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NEW 1 of 56: Saudi Aramco Oil Company (Saudi Aramco) Yanbu Refinery Instruction Manual
NEW 1 of 56: Saudi Aramco Oil Company (Saudi Aramco) Yanbu Refinery Instruction Manual
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Advise all employees and contractors of their loss prevention responsibilities and regularly
measure their performance;
Evaluate, identify and eliminate or manage safety risks prior to beginning any operation or activity
and continue to review such risks, complying with all applicable laws and regulations;
Communicate loss prevention objectives and procedures regularly to employees and all affected
parties;
Train employees and provide resources to maintain job competencies, including loss prevention
responsibility and accountability;
Design and construct Company facilities utilizing recognized best technology and practices to
safeguard property and people;
Require that contractors, suppliers and others adhere to the Companys loss prevention policies,
procedures and goals;
Prepare for emergencies and other contingencies and respond promptly and effectively to any
incidents or accidents resulting from operations;
Review and improve the Companys loss prevention program and performance continuously.
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The objective of this process is to ensure compliance with all established company
inspection procedures/programs and maintain required level of asset integrity throughout
Yanbu Refinery facilities.
Applicability
4. Corporate Expectations: YRD follows all the guidelines as outlined in SMS Manual
Refer to YRD SMS website.
5.
Process Description
The main objective of this comprehensive inspection programs is to enable YRD inspection
team to comply with all corporate requirement for assets integrity and to highlight
deficiencies observed that require repair or action necessary to prevent further damage to
the equipment. Also this document specifies the responsibilities of all YRD personnel
pertaining to assets integrity. The area inspector shall use this document as a supplement to
the plant inspection index (00-SAIP-71). This document includes a section for each
inspection procedure/program which will include a brief description of the
procedure/program, a list of the related standards and engineering/inspection procedures, a
table which specifies the responsibilities and the required documentations and where it will
be filed.
6.
Responsibilities
a) YRD Inspection Unit Supervisor owns the overall responsibility for implementing the
periodic inspections at Yanbu Refinery facilities
b) YRD Inspection Unit Field Supervisor shall provide qualified inspection personnel to
conduct the inspection activities including tests. The Inspector will examine the system
during the inspection/test and issue a necessary test report per established
procedures after successful completion of each inspection/test. The inspection results
shall be retained as a record in the Inspection Filing System.
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c) The refinery Operation Foreman is responsible to ensure that all required inspection
programs are conducted in his plant limit as per inspection schedules.
d) The Supervising Operator of each unit shall be responsible to ensure that all proper
work permits have been issued.
e) The Area Maintenance/T&I engineer shall be responsible for providing the necessary
manpower and equipment (crane, man lift, scaffolding, etc) to perform the required
inspection activities and to rectify deficiencies.
f) The Area Process Engineer shall be responsible for preparing and distributing the
required procedures (hydrotest procedures, leak test, shutdown, start up etc) as
required to assist in conducting the inspection activities in accordance with relevant
company standard, or YRD internal procedures.
g) The detail responsibilities of all inspection programs are listed under in each program
7.
YRD Engineering Inspection Unit shall provide required functional training to meet the
competencies required for conducting inspection activities per company established guidelines
and programs. YRD Inspection Unit is following the corporate training requirements to certify YRD
inspectors and all required courses and exams shall be fulfilled prior to certifying the inspectors.
8.
Documentation
The Engineering Inspection Unit shall complete, issue and distribute the inspection reports
including test information sheets per relevant Saudi Aramco inspection procedures to the
area Operations Foreman and area OME team. Records of all tests shall be maintained by
YRD Inspection Unit as will be detailed in the documents for each inspection
procedures/programs.
9.
References
All relevant references are indicated under each Procedure/Program in this document.
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SAEP-306 Assessment
SAEP-325 Inspection
SAEP-1141
SAEP-1143
Radiographic Examination
SAEP-1144
SAEP-1145
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SAEP-1146
SAEP-343 Risk Based Inspection (RBI) for In-Plant Static Equipment and piping.
00-SAIP-80
32-SAIP-11
01-SAIP-02
SAES-C-001
SAES-D-001
SAES-D-109
SAES-E-004
SAES-E-007
SAES-F-007
SAES-H-001
SAES-N-110
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API 510
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Responsibilities:
Activities
Assigned to
Inspection
PMT/PID
Activities during
construction
period
Remark
Project inspector shall perform the following activities:
PMT
PMT/PID/PROPONENT inspects the static equipment for final boxPID inspector up and signs the final box-up certification.
YRD inspector
Inspection
Activities(during
T&I and up on
request)
Area
inspector
Maintenance
Activates
T&I engineer
Work Permit
Area
operation
supervisor
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Procedures
(hydrotest, leak
test, shutdown,
start-up etc)
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Inspect chemical Area process Inspect the internal chemical material (Desiccant, Sieve,
material
engineer /
Catalyst, etc) and provide the required specification if
Operation
replacement is needed.
supervisor
Documentations:
1. Approved SIS, Drawings, P&ID, SAIC and final box up certification
2. Pre-T&I Report Issued by the area inspector
3. Inspection Recommendations Issued by the area inspector
4. Post T&I Report Issued by the area inspector
5. Deviation Letter to postpone the scheduled T&I initiated by operation.
The area inspector shall document the above documentations in:
1. Equipment file
2. Equipment file in the shared folder
3. Update the SAIF program if required
3- External mechanical Inspection of Equipment, piping and components:
Procedure/Program Description:
External visual inspection of all mechanical equipments, piping and their components are
carried out as per the Inspection Schedule established as per the guidelines indicated in
SAEP-20 which specifies 24 months interval for onshore areas.
Referenced Standards/Procedures
00-SAIP-75
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Responsibilities:
Activities
Assigned
to
Remark
Inspection Inspection
Activities Unit
Supervisor
Area
inspector
Ensure that all equipment within his area of responsibility is listed in the EIS
specifying inspection intervals as required by SAEP-20. A schedule of
twoyear external inspections shall be made available and is updated
regularly.
Perform two-year external inspection of all existing equipment within his
area listed in the approved EIS with the corresponding checklist(s);
per
attachments of 00-SAIP-75. Complete individual checklist for
pressure
equipment per SAEP-20, paragraph 5.5.8. Use the 00-SAIP-75 checklists
as
references only when inspecting piping if not individually listed in the
EIS.
Inspection of civil structure will be inspected (every two-year) by
the
assigned civil inspector while electrical equipment will be
inspected
(annually) by the assigned electrical inspector.
Prepare a detailed on-stream inspection report of the present condition
of
the equipment highlighting the deficiencies observed that require
repair or
action necessary to prevent further damage to the equipment and
issue
IWS or LBE if required.
Request engineering evaluation if deemed necessary.
Maintenan Maintena
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lift,
scaffolding, etc) to perform the required inspection activities and rectify
the
highlighted deficiencies.
Activates
nce
Engineer
Work
Permit
Include providing the necessary work permit and initiating deviation letter
Area
to
operation postpone the T&I.
supervisor
Documentations:
1. Completed external check list survey
2. Inspection Worksheet highlighting the Inspection Recommendations
The area inspector shall document the above documentations in Equipment file and
Inspection unit shared folder
4- Inspection of Spring Support:
Procedure/Program Description:
Inspection requirement for spring supports for pipes and equipment during routine visual external
inspection. Inspections of spring support are required as per 00-SAIP-75. Inspection is required
to examine all items related to Spring support such as I beam support, beam attachment pin,
hanger attachment, integrity of clamps, eye-bolts & hanger rod, spring coil & housing, Hot/cold
load positions marked on tap plate, spring coil fully compressed, coating & galvanizing, safety
hooks availability, davits & lifting lugs in good condition and spring identification. Test results are
reviewed and any defect found shall be sent to Area operation foreman to rectify.
Referenced Standards/Procedures
00-SAIP-75
Responsibilities:
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Remark
Inspection
Projects Inspector
Activities during
construction
period
Assure that all spring supports for new project are working
Inspection
Activities
Area inspector
Work Permit
Area operation
supervisor
Maintenance
Activates
Maintenance
Technician
Documentations:
The area inspector shall document the above documentations in:
1. Equipment file
2. Equipment file in the shared folder
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5- Inspection Of thermowell:
Procedure/Program Description:
Inspection is carried out on all thermowell that can be dismantled during plant T&I. Inspection
of all thermowells is conducted as per standard drawing AB-036019 and inspection results
are reviewed and any defect found shall be sent to Area operation foreman to rectify. All
results are recorded and filed along with the post-T&I reports.
Referenced Standards/Procedures
SAES-J-400
Temperature
AB-036019
Responsibilities:
Activities
Inspection
Activities
during
construction
period
Saudi Aramco:
Assigned to
PMT & new
project design
reviewer
Remark
Assure that all thermowells are made of 316 SS. Other materials
shall be approved by CSD.
Assure the proper length of thermowell is installed.
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Activities
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and
inform
Documentations:
List of all thermowells inspected during each T&I. The area inspector shall file this documentation in:
1. Equipment file
2. Equipment file in the shared folder
6- Hydrostatic Testing for repaired
components Procedure/Program
Description:
Hydrostatic testing of equipment and piping is conducted after completing major repair,
renovation or alternation and replacement in kind of equipment and piping as per the
guideline given the following standards / procedures.
Referenced Standards/Procedures
SAES-A-004
SAES-L-150
00-SAIP-06
GI-0002.102
ASME B31.1
Saudi Aramco:
Power Piping
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NB 23
Responsibilities:
Assigned
Activities
to
Inspection
Activities
Area
inspector
Remark
Include the following:
Request and witness pressure testing for all equipments/lines which
undergo a repair or alteration that affect the equipments/lines
integrity. The test shall be as per SAES-L-150 and in accordance with
the fabrication code. As a guideline for boiler hydrotest during T&I or
repair work, request and witness pressure test as per boiler data
sheet. For major repair, the pressure test shall be 1.3 X-DP. If no
repair was done, the test shall be up to the DP. This test is required to
check tube integrity. For shell and tube heat exchanger, request and
witness hydrotest for the shell and another hydrotest for the tube
after each T&I and before the exchanger is turn to operation.
The
tests shall be as per equipment data sheet and fabrication code.
Test media shall be approved by standards. Pneumatic 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 equipment file for
each pressure test.
Area
Procedures process
(hydrotest, engineer
shutdown,
start-up
etc)
Work
Permit
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Area
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operation
supervisor
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SAEP-20
SAEP-309
Responsibilities:
Activities
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Prepare Original
EIS
PMT / Inspection PMT shall prepare and route for approval the EIS for
Unit supervisor
Equipment built by PMT. Inspection Unit supervisor shall
prepare and route for approval the EIS For equipment built
by YRD maintenance.
Maintaining the
EIS
Area inspector
Documentations:
The Approved EIS shall be filed by the area inspector in:
1. Equipment file located in the Inspection filling room
2. Update the SAIF program if required
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The small bore piping nipple inspection is intended to monitor the condition of in service
piping nipple of size 1 inches and smaller. Internal / external corrosion and welding defects
will be monitored. Each piping system will be categorized as per the corrosion severity and
classified as per the potential consequence on leaks. Based on corrosion category and piping
class, the inspection frequency will be fixed.
The piping inspection frequency is determined from the Nipple Inspection Intervals Matrix
provided in 01-SAIP-01. The subsequent nipple inspection will be adjusted based on the
inspection findings. Inspection frequency for injection points shall not exceed three years as
stipulated in 01-SAIP-02.
Radiography testing (RT) will be the primary inspection method for the internal or external
corrosion of the nipple, for all services including cryogenic service. If welding defects were found
during the inspection, the acceptance criteria provided in 01-SAIP-01 shall be utilized. Ultrasonic
Thickness (UT) inspection shall be utilized when RT is not conclusive. In addition to radiography,
MT or PT should be used to inspect for cracks in vibrating services or austenitic stainless steel
welds. Visual inspection should be performed on all pipe nipple systems to determine the need
for replacement or repairs due to external corrosion, threads not covered by seal weld, vibration
fatigue or possibility of overloading of the nipple.
The nipple shall be replaced when the retirement thickness is reached. The retirement thickness
shall be the lower of the minimum thickness by code and the structural minimum thickness. If the
retirement thickness has not been reached but there is metal loss, the remaining life shall be
calculated. The nipple shall be replaced if the remaining life is less than either the next inspection
interval or the next T&I. If the piping system cannot be shut down for nipple replacement, temporary
repair shall be considered until replacement in the next schedule T&I.
The nipple shall be replaced when the retirement thickness is reached. The retirement thickness
shall be the lower of the minimum thickness by code and the structural minimum thickness. If the
retirement thickness has not been reached but there is metal loss, the remaining life shall be
calculated. The nipple shall be replaced if the remaining life is less than either the next inspection
interval or the next T&I. If the piping system cannot be shut down for nipple replacement, temporary
repair shall be considered until replacement in the next schedule T&I.
All pipe nipples that have been identified as having incorrect metallurgy for the piping system
should be removed and replaced regardless of the remaining wall thickness. All alloy
replacement nipples, valves and welds should be evaluated using an approved Positive
Material Identification (PMI) instrument before installation.
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Nipples which are not braced and subjected to vibration should be adequately braced per
SAES-L-310, paragraph 20.2.3 and Saudi Aramco Standard Drawing AB-036521 to prevent
future fatigue failure.
Referenced Standards/Procedures
01-SAIP-01 Small Nipple Inspection Program
AB-036521 Bridge Weld and Typical Brace Seal Welded and Socket Welded Valves on
Process Lines
Responsibilities:
Activities
Assigned to
Remark
Inspection Activities
OSI Coordinator
NDT Technician
Work Permit
Area
supervisor
Maintenance Activates
Documentations:
1. Piping Isometric
2. NDT Report
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Referenced Standards/Procedures
SAEP-1135
SAIF
PMT
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constructi
on
Inspection YRD
Assure the availability of an active OSI program and all unit personnel
have an
Activitie
s
Inspectio
n
Unit
Supervis
or
Corrosio
n
Engineer
and Area
Saudi Aramco:
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OSI
Coordinator
Inspection
Field
Supervisor
[ X ] New Instruction
Area
Inspector
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Process
Engineer
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monitored plant equipment as per OSI due
reports and prepare OSI isometric drawings
of added piping and equipment.
Work Permit
Maintenance Activities
NDT
Technician
Operation
Supervisor
Maintenance
Engineer
Documentations:
1. OSI isometric drawings.
2. TML readings.
The OSI coordinator shall document the above documentations in SAIF OSI module.
10- Dead leg survey and monitoring in plant areas:
Procedure/Program Description:
Dead 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 its
pipe diameter, or 1.22 m (4 ft) whichever is less. All dead legs shall be eliminated in the
design stage by modifying the piping system during project review. If the deal legs cannot be
eliminated at piping system, then YRD inspection Unit will monitor such dead legs through
the On- Stream Inspection (OSI) Program as per SAEP-1135.
For new projects and in case where a piping section is identified as dead leg and it is not
avoidable from a construction point of view, then it shall be added to OSI and a concurrence
letter shall be signed by:
-
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In normal operation, if a piping configuration is suspected to be a dead leg, then the plant
process engineer and YRD Corrosion engineer should be contacted to evaluate the case and
decide whether it is a dead leg or not. YRD has developed additional reference to help in
evaluating the dead leg conditions (Letter # KGP-92-09). If this piping configuration was
considered as dead leg, then the following activates will be made:
-
The dead leg will be monitored every year for five (5) years.
After five (5) years of monitoring if no defect is found, then this dead leg can be
removed from OSI program.
If we found any metal loss even low corrosion rate, then the dead leg will be kept in
OSI program. In addition, this dead leg should be targeted for elimination if possible.
When pipe minimum thickness (tm) is reached, an inspection work sheet or logbook
entry shall be issued by area inspector to fix deficiency.
Referenced Standards/Procedures
SAES-L-310
SAEP-1135
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Responsibilities:
Activities
Assigned to
Design
Activities
PMT
& new Assure that dead legs are eliminated in the design stage by
project
design modifying the piping system during the project review.
reviewer
Remark
YRD
inspection Include the following:
unit supervisor
Highlight any dead leg, during construction phase, to PMT 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.
Issue an Inspection Worksheet or logbook entry is issued as
needed.
Inspection Field
Supervisor
Area inspector /
OSI coordinator
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Area operation
supervisor
Maintenanc Maintenance
e Activates engineer
Documentations:
1. List of dead legs in the plant.
2. Dead leg worksheet or logbook issued by area inspector.
The area inspector shall document the above documentations in:
1. Equipment file
2. Equipment file in the shared folder
3. Upload the OSI reading for all identified dead leg into the SAIF program
11- Dummy leg survey and monitoring:
As the result of technical alert 002/01 dated 2/28/2001, all dummy legs in the plant, especially
in hydrocarbon service will be surveyed by the area inspector and any deficiencies will be
reported to area operations foreman for remedial action through IWS.
Referenced Standards/Procedures
ALERT-01-002 Deficiency of Dummy leg support elbows
Responsibilities:
Saudi Aramco:
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Approved
Activities
Replaces
Assigned to
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Remark
Inspection
Activities
Area inspector
Maintenance
Activities
Area
Maintenance
engineer
Documentations:
1. Dummy legs survey for each plant.
2. Dummy legs worksheet or logbook issued by area inspector.
The area inspector shall document the above documentations in:
1. Equipment file
2. Equipment file in the shared folder
Injection points include those for injecting corrosion inhibitors, PH control, anti-foam and methanol.
Injection Circuits
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For the purpose of monitoring, the Injection circuits shall begin at 300 mm (or 3D where D
is the nominal pipe diameter whichever is greater) upstream of the injection point and end at
the second change in the flow direction or 7.6 meters beyond the first change in flow
direction (whichever is less) downstream of the injection point.
Thickness Measurement Locations
The Thickness Measurement Locations (TML) within the injection circuits should be
located in the process piping at the below mentioned locations:
Downstream of the injection point defined as: D, 5D, 10D, midway between the
Injection point and the first change in direction (if they are more than 7.6 m apart).
At the end of the circuit downstream of the injection point as defined above.
Referenced Standards/Procedures
SAIF
Dcumentations:
1. OSI isometric drawings.
2. TML readings.
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The OSI coordinator shall document the above documentations in SAIF OSI module
Responsibilities:
Activities
Assigned to
Inspection YRD
Activities inspection
unit
supervisor
Remarks
The Inspection Unit Supervisor shall be responsible for:
Assigning inspectors/technicians to gauge pipe wall thickness at the
injection point Thickness Measurement Location (TML).
Approve repair, modification or replacement recommendations for the
injection points.
Assure that the OSI inspection program is implemented in YRD facilities.
OSI
Coordinator
Corrosion
Engineer
Identifying all the injection points in the plant (coordinate with the plant
process engineer in this task).
Reviewing/recommending modifications or replacement of injection
points.
Determine Inspection interval based on the corrosion rate
Evaluate the need to add/delete TML locations based on the corrosion rate
of the circuits
Saudi Aramco:
Coordinate with the area inspector to issue IWS if pipe spools require
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Verifying the areas that are approaching T-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 OSI inspection program is implemented in his plant and
make sure that all OSI readings are updated in the SAIF program on
time(no Overdue)
NDT
Technician
Work
Permit
Operation
supervisor
Maint.
Activities
Maintenance
Engineer
Include providing the necessary manpower and equipment (crane, man lift,
scaffolding, etc) to perform the required inspection activities and rectify
the highlighted deficiencies.
Saudi Aramco:
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Piping systems made of carbon steel and operating temperature between 25F (-4C)
and 250F (121C).
Piping systems made of carbon steel and operating temperature above 250F (121C)
or below 25F (-4C) but in intermittent service.
Piping systems made of austenitic stainless steel and operate between 100F (38C)
and 400F (204C).
Piping located in areas exposed to mist overspray from cooling water towers.
Dead legs and protrusions from insulted piping that operates at different temperatures of
the main line.
Steam traced piping systems that may experience tracing leaks, especially at tubing
fittings beneath the insulation.
Piping systems with deteriorated coating and wrapping, damaged insulation cladding, or
insulation that might be damaged by piping vibration.
All penetrations or breaches in the insulation jacketing such as dead legs (vents,
drains, instrument tapping and similar items), pipe hangers and supports and steam
tracing tubing penetrations.
Bolted-on shoes.
Damaged or missing insulation jacketing or when the seams of the insulating jacketing
are located on the top of horizontal piping.
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Low points in piping systems that have a known 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 in
high-alloy piping systems.
Insulated equipment shall be inspected for CUI if any of the following conditions apply:
Equipment operating above 250F (121C) or below 25F (-4C), but in intermittent operation.
Some locations of Insulated vessels and tanks that are susceptible for CUI may be
exposed to CUI more than the rest of the equipment. Examples of highly suspect areas
include, but not limited to the following:
Samples of the CUI 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 NDT or insulation removal. Quantities of inspection samples are as
shown in Table 1. Piping classification is per section 6.2 of API-570. All vessels and
tanks are to be classified as class 1
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Table1
Class
75%
50%
50%
33%
25%
10%
If the inspection of the selected locations revealed significant CUI, then the percentage of the
selected location shall be increased. If the system is known to have a good coating system,
or if the system has a good history from previous inspections for CUI, then the percentage of
the selected locations can be decreased up to 50% of the amounts given in Table 1.
Referenced Standards/Procedures
SAEP-20
SAEP-1135
00-SAIP-75
SAES-N-001
API 570
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Responsibilities:
Activities
Assigned to
Inspection
Activities
Remark
Area process
engineer
Work Permit Area operation Include providing the necessary work permit
supervisor
maintenance to start maintenance activities.
Saudi Aramco:
[ X ] New Instruction
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[ ] Change
and
inform
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Activates
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Approved
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Documentations:
1. List of Susceptible Systems for CUI.
2. CUI worksheet or logbook issued by area inspector.
The area inspector shall document the above documentations in:
1. Equipment file
2. Equipment file in the shared folder
3. Update the SAIF program if required
14- Thermograph inspection Survey of cold insulated equipment and piping
Procedure/Program Description
Thermograph Inspection of cold insulated drums, tanks and piping is carried out in order to
determine the damaged insulation and hot spots. These areas will be later added to T&I
scope to remove the insulation at the damaged areas and hot spot areas for visual and NDT
inspection and remedial action.
Referenced Standards/Procedures
None
Responsibilities:
Saudi Aramco:
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[ ] Change
[ ] Addition
Issue Date
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NEW
Approved
Activities
Assigned
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Remark
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to
Inspection Activities
YRD inspection
unit supervisor
Inspection Field
Supervisor
Work permit
YRD Qualified
Inspector
Area Operation
Supervisor
Maintenance Activates
Documentations:
Thermograph inspection survey report. The inspector shall document this report in:
1. Equipment file
2. Equipment file in the shared folder
15- Cathodic Protection System Inspection
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Procedure/Program Description:
YRD Operation/Inspection Unit will conduct monthly and annually surveys to monitor the
cathodic protection (CP) systems as specified in SAEP-333 and SAIP-02. The CP system
must be monitored to ensure that equipment or structures receive adequate protection.
Monitoring surveys for tank bottoms and in-plant buried piping will be conducted annually by
electrical inspection unit. The survey data shall be reviewed, analyzed and carried out
recommendations for corrective action.
Anode bed monitoring and maintenance:
Evaluate the performance of each anode bed annually prior to the scheduled annual potential
survey. The evaluation includes measuring the current output for each individual impressed
current/galvanic anodes and current in the negative cables. Measure the current output
From the voltage drops across the shunts if they are installed at the anode cable
terminals inside the anode junction boxes
By a DC clamp-on-ammeter, if no shunts are available
Calculate an estimate of the service life of the anode beds. For single or multiple
negative cables, measure the current in each cable as above.
For junction box, annually check will be conducted for all anode junction box connections
and fittings for cleanliness and tightness. During annually check, perform any required
maintenance as follows:
Take apart all connections and bolted fittings and clean with an approved safety solvent.
Apply Burndy Penetrox E oxide inhibiting compound (or equivalent) to all
cables and connections. When finished, reinstall them.
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In YRD, there are two types of rectifiers oil cool and air cool rectifiers. Oil cool rectifier is
represented at DGA and air cool rectifier at Utilities. These rectifiers are required two types
of inspection monthly and annually inspections.
Monthly inspection:
Either Operations or Maintenance personnel who normally visit the site on a regular
basis for purposes other than those relating to cathodic protection can perform
these procedures.
Check rectifiers on a monthly basis and record the output volts and amps.
Record the rectifier output data on the attached data sheet.
Report immediately any abnormal rectifier operation to the Inspection Unit.
Annual inspection:
Record rectifier output volts and amps.
Visually inspect the cabinet, terminals, and components for any damage.
For oil cool rectifier only, check the oil level, temperature and perform
sample check as follows:
1. Open the drain spout and collect approximately one liter of oil in a clear glass
container. If sediment, sludge, or water drains with the oil during sampling, continue
draining until the contaminant has been flushed out. Then collect approximately one
liter of oil. If the sediment has not been flushed out after four liters of oil have
drained, the rectifier should be completely drained and filled with new oil.
Record all data taken during the annual rectifier check on the data sheet shown in
SAEP-333A, appendix J, pages 12.
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Referenced Standards/Procedures
GI 428.003
SAES-X-600
SAEP-333 Cathodic
SAEP-333A
Documentations:
List of CP Systems at YRD:
Responsibilities:
Activities
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Assigned to
Remark
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Activities
NEW
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YRD inspection Inspection unit supervisor shall be responsible for the following:
unit supervisor Assure that an inspection programs for CP is established and being
inspected and monitored.
Area foreman Area foreman shall be responsible for the following:
Ensure that All CP systems are being checked.
Electrical
maintenance
supervisor
Area electrical Area electrical technician shall be responsible for the following:
technician
Conduct the CP rectifier monthly check and record output data in
data sheet.
Inspection
Field
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Supervisor
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Area electrical
inspector
Work Permit
Area operation Area operation supervisor shall be responsible for the following:
supervisor
Provide the necessary work permit and inform maintenance to
start maintenance activities.
Engineering
Activities
YRD corrosion
engineer
Maintenance
Activates
Maintenance
engineer
Saudi Aramco:
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Procedure/Program Description:
Piping systems are generally subject to both internal and external corrosion. The internal
corrosion is considered to be challenging as well as expensive in practice. It has been
observed that internal corrosion could potentially reduce the pipe wall thickness much more
than external corrosion. In general, it becomes highly critical to mitigate internal corrosion
and reduce the risk of leakage in piping system. For that, YRD has installed corrosion
monitoring system to monitor internal corrosion and corrosion inhibitor performance inside
piping systems. COSASCO 2" corrosion monitoring assemblies are the CMSs, which are
installed in YRD. This CMS is designed to monitor corrosion behavior on line.
COSASCO 2" CMS can be installed and retrieved by using the following equipments:
1- RBSA retrievers
2- Service valves
3- Bleed valve and a pressure gauge to allow the operator to monitor the internal
pressure during use
These equipments are designed to install and retrieve the COSASCO 2" corrosion
monitoring assemblies... safely, without shutdown. But in order to complete retrieving or
installing activities safely comply with the below requirements:
1- Safe operation requires a minimum of 2 trained operators.
2- Do not use retrieval equipment unless you have been trained in its safe operation.
3- If it has been longer than 90 days since your last operation, you should review the
manual and first practice on a dummy fitting prior to use.
4- Make sure you have complied with all plant safety requirements and
environmental regulations.
5- Identify the type media, its pressure and temperature.
6- Review material safety data information on the media prior to operation.
7- Insure you have all the required safety equipment for the given media, "i.e. hard hat, safety
glasses, protective clothing, safety gloves, respirator, spill safety equipment, etc...
8- Any actions which could vary system pressure such as surges caused by opening and
closing of valves and chokes should be delayed until completion of retrieval operations.
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10- Note wind direction prior to starting operations involving hazardous products.
Referenced Standards/Procedures
Corrosion Monitoring OI&MM
Project Specification for Corrosion Monitoring System
Responsibilities:
Activities
Assigned to
Inspection
Activities
YRD inspection
supervisor
Remark
unit Inspection unit supervisor shall be responsible for the
following:
Assure that an inspection programs for Monitoring of CMS
is established and all CMSs are being inspected and
monitored.
Engineering YRD corrosion engineer Corrosion engineer shall be responsible for the following:
Activities
Conduct monthly survey through PI system.
Work Permit
Area Forman/operation Include Providing the necessary work permit and inform
supervisor
maintenance to start maintenance activities.
Documentations:
1- List of CMSs at YRD.
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00-SAIP-75
SAEP-309 Inspection
SAES-A-114
Responsibilities:
Activities
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Assigned to
Remark
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Activities
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YRD inspection Assure that the civil inspection program is implemented for all
unit supervisor
YRD electrical equipment.
civil Inspector
Maintenance
Activities
Work Permit
Area operation
supervisor
Documentations:
1. Issued civil inspection checklist
2. Inspection worksheets or Log Book Entry if needed.
3. Monthly status report with clear tracking system detailing all open worksheets and
items to operations in a monthly basis.
The civil inspector shall file the above documentations on:
1- Shared folder
2- Inspection unit file room
3- Upload it into SAIF system (Inspection Worksheet only).
18- Inspection of Plant Buildings (Civil Inspection).
Procedure/Program Description:
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Visual civil inspection of plant buildings such as OME, PIB, Substations, Lift stations etc shall be
conducted as per guidelines given in the civil section of EIS and the below engineering
procedure.
A concrete database is being created and will be uploaded in the SAIF system. The database
will contain all the equipment and piping foundations, footing and sleepers and all fireproofing
in the plant. The concrete foundations will be classified as per the grading given in SAEP-309
for concrete and grouting.
Referenced Standards/Procedures
SAEP-309 Inspection
SAEP-S-020
SAES-S-010
Sanitary Sewers
00-SAIP-75
Responsibilities:
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NEW
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Activities
Replaces
Assigned to
Page No.
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Remark
Work Permit
Maintenance
Activates
Maintenance engineer
Documentations:
1. Civil Inspection Report which shall be filed in the inspection filling room and the shared folder
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shall be given more attention during inspection. Any crack in the fireproofing shall be
evaluated to find out if it is indicating any sign of corrosion. Inspection windows might be
made to verify any external sign of corrosion under fireproofing. If corrosion is found then
the fireproofing shall be removed to expose all corroded area.
For Structures and Pipe Racks
Visual inspection shall be performed to find out any external sign of corrosion under
fireproofing. Inspection windows in form of horizontal stripes should be made if deemed
necessary. They should intersect cracks at random locations. If corrosion is found, then
all corroded area shall be exposed.
If any NDT can be applied to inspect the equipment under fireproofing for corrosion, then
inspection windows or stripes should not be made.
Referenced Standards/Procedures
00-SAIP-74 Inspection of Corrosion under Insulation and Fireproofing
Responsibilities:
Corrosion under insulation (CUI) and corrosion under fire proofing (CUF) share the
same responsibilities. Follow the responsibility section of the CUI program.
Documentations:
The civil inspector shall issue a report to document his findings during the annual
survey of the fire fireproofing in the plant. This report should be stored in the:
1- Equipment file
2- Equipment file in the shared folder
3- Upload it into SAIF system(Inspection Worksheet only)
20- External Inspection of Electrical Equipments:
Procedure/Program Description:
Saudi Aramco:
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An annual external inspection for all electrical equipment should be conducted and
deficiencies shall be reported for area operation foreman to rectify. The internal
inspection of plant equipment shall be made as required at installation, upon request
or during scheduled test and inspections (T&Is). The external inspection of the below
electrical equipment in the plant shall be conducted annually:
Conduit systems, cable trays and cable systems for support and continuity.
Enclosures and junction box for covers, conduit seals and drains.
Electrical Equipment such as motors for physical damage, oil leaks, and
overheating.
Referenced Standards/Procedures
00-SAIP-51
Electrical Inspection
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15-SAIP-50
15-SAIP-51
16-SAIP-11
DE-014949
DE-093684
00-SAIP-75
SAES-P-101
SAES-P-103
SAES-P-104
SAES-P-107
SAES-P-111
Grounding
SAES-P-113
SAES-P-114
SAES-P-116
SAES-P-119
Onshore Substations
SAES-P-121
SAES-P-123 Lighting
SAES-P-126
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Responsibilities:
Activities
Assigned to
Inspection
Activities
YRD inspection
supervisor
Electrical Inspector
Remark
unit 1. Assure that the electrical inspection program is
implemented for all YRD electrical equipment.
2. Perform External Electrical Inspection on all
industrial plant electrical equipment and Operation
Support Facilities.
3. Review maintenance work schedule and inspect
the performed electrical work as needed.
4. Report immediately to Operations foreman all
deficiencies which are found during the electrical
inspection survey through Log book entry or
Inspection worksheets as needed.
5. Follow up with the area electrical technicians to
rectify these deficiencies.
6. Perform internal inspections in all open electrical
equipment during T&Is.
7. Review all electrical engineering design package
and inspect all new electrical installation in the
plant.
Maintenance
Activities
Work Permit
Area operation supervisor provide the necessary work permit (as needed)
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[ X ] New Instruction
[ ] Complete Revision
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Issue Date
Replaces
NEW
Technical
support
Approved
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Documentations:
1- Issued electrical inspection checklist
2- Inspection worksheets or Log Book Entry if needed.
3- Monthly status report with clear tracking system detailing all open worksheets and
items to operations in a monthly basis.
The electrical inspector shall file the above documentations on:
1- Shared folder
2- Inspection unit file room
3- Upload it into SAIF system (Inspection Worksheet only).
21- Thermography inspection for electrical equipment
Procedure/Program Description
Breaker panels, switchgear, motor control centers, and bus bar connections. The infrared
camera is a predictive maintenance device that can reveal loose connections, unbalanced
loads / phase problems and overloaded circuits.
Referenced Standards/Procedures
The procedure of conducting Thermography Inspection for electrical equipment is included in:
00-SAIP-51-5.9
Saudi Aramco:
Electrical Inspection
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Responsibilities:
Activities
Assigned to
Remark
Inspection
Activities
Electrical Inspector
Maintenance
Activities
Area Maintenance
engineer
Work Permit
Area operation
supervisor
Documentations:
1- Infrared camera report
2- Inspection Work Sheet or Log Book Entry if needed
The inspector shall file the above documentations in:
1- Shared folder
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[ X ] New Instruction
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2-
3-
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22- Issuing and monitoring Inspection Worksheets and Log Book Entry
Refer to SMS # 5.7
23- Technical Alerts Tracking System:
Procedure/Program Description:
Technical alerts tracking system is implemented as per the guidelines indicated in SAIP-77.
This system should be established to track all the technical alerts that are published by S.
Aramco. YRD technical alerts coordinator should assign the alerts to the right team
(electrical, mechanical, instrument ...) to evaluate them and take the required action.
Referenced Standards/Procedures
SAIP-77
Responsibilities:
Activities
Establish technical
alerts tracking system
Saudi Aramco:
Assigned to
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Documentations:
The technical alerts coordinator shall document the evaluation and action from the assigned team.
KGP technical alerts tracking system available in the KGP shared folder
SAES-A-206
00-SAIP-07
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Responsibilities:
Activities
Assigned to
Remark
Inspection
Activities
Maintenance Maintenance engineer Include providing the necessary manpower, material and
Activities
equipment (crane, man lift, scaffolding, etc) to perform the
required maintenance activities.
Documentations:
1- Material data sheet.
2- Output results of reading.
The area inspector shall document the above documentations in:
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1- Equipment file
2- Equipment file in the shared folder
Saudi Aramco:
[ X ] New Instruction
[ ] Complete Revision
[ ] Change
[ ] Addition