PCSB Inspection and Maintenance Guidelines Volume 1

MY ALL M 04 001 (V1)
Rev. 1 December 2000
PCSB
INSPECTION AND
MAINTENANCE GUIDELINES
(VOLUME 1)
PETRONAS CARIGALI SDN BHD

Inspection And Maintenance Guidelines (V1) MY ALL M 04 001(V1)
INSPECTION AND MAINTENANCE GUIDELINES
Main Contents
Foreword
Distribution List
Amendment Summary
Preface
Abbreviations and Acronyms
Referenced Documents
Section 1 Introduction
Section 2 Document Revision Control
Section 3 Offshore Structures
Section 4 Pipeline And Risers
Section 5 Piping Flowlines
Section 6 Pressure Vessels And Steam Boilers
Section 7 Rotating Equipment
Section 8 Storage Tanks
Section 9 Cranes And Lifting Equipment
Section 11 Subsurface Main Facilities
Section 13 Instrumentation And Control Systems
Section 14 Electrical Equipment And Installations
Section 15 Telecommunication Facilities
Appendices Appendix 1 Hierarchy Of Documents In PETRONAS

Carigali Sdn Bhd
Appendix 2 Inspection And Maintenance Key
Performance Indicators
Appendix 3 Inspection And Maintenance Process &
Responsibility
Appendix 4 Inspection And Maintenance Summary
Matrix
Appendix 5 Discussion Notes With Relevant Parties
Appendix 6 CIMG Change Proposal Form
PETRONAS CARIGALI SDN BHD Preliminary
Page i
FOREWORD
Authority for original issue
Issue Approval
Issue of this document has been formally approved by:
Signature:
Name:
Reference Indicator:
Position:
Date:
Issue Agreement
Agreement for issue of the document was made by the
following:
Signature:
Position:
Date:
Document Custodian
The following person has been assigned as the document

custodian:
Name:
Reference Indicator:
Position:
Proprietary Information
This document contains proprietary information belonging to

PETRONAS PCSB Sdn Bhd and must not be wholly or partially reproduced nor
disclosed without prior permission from PETRONAS PCSB Sdn Bhd.
Page ii
DISTRIBUTION LIST
No. DIVISION Department/ DESIGNATION Copy

Section No.
1 custodian Master Master Copy 1
2 DEVELOPMENT DDE Manager, Engineering 2
3 DDE/3 Head, Underwater Engineering 3
4 DCE Manager, Construction 4
5 DCE/1 Head, Material and Corrosion 5
6 DD Lib. DDE Library 6
7 SABAH SD General Manager, SBO 7
8 OPERATION STS Manager, Technical Services 8
9 STS/1 Head, Subsurface Engineering 9
10 STS/2 Head, Surface Engineering 10
11 STS/3 Head, Specialist Maintenance 11
12 STS/4 Head, Quality Control 12
13 STS/5 Head, Inform. Technology 13
14 SOS Manager, Semarang Operations 14
15 SOS/1 Head, Operations 15
16 SOS/2 Head, Asset Planning 16
17 SOT Manager, Tembungo Operations 17
18 SOT/1 Head, Operations 18
19 SOT/2 Head, Asset Planning 19
20 SPL Manager, Planning 20
21 SBO Lib. SBO Library 21
22 SARAWAK BD General Manager, SKO 22
23 OPERATION BTS Manager, Technical Services 23
24 BTS/1 Head, Subsurface Engineering 24
25 BTS/2 Head, Surface Engineering 25
26 BTS/3 Head, Specialist Maintenance 26
27 BTS/4 Head, Quality Control 27
28 BTS/5 Head, Inform. Technology 28
29 BON Manager, Northern Operations 29
30 BON/1 Head, Operations 30
31 SARAWAK BON/2 Head, Asset Planning 31
32 OPERATION BOS Manager, Southern Operations 32
33 BOS/1 Head, Operations 33
34 BOS/2 Head, Asset Planning 34
35 BOT Manager, MCOT Operations 35
36 BOT/1 Head, Operations 36
37 BOT/2 Head, Asset Planning 37
38 BPL Manager, Planning 38
39 SKO Lib. SKO Library 39
Page iii
No. DIVISION Department/ DESIGNATION Copy

Section No.
40 PENINSULAR PD General Manager, PMO 40
41 MALAYSIA PTS Manager, Technical Services 41
42 OPERATION PTS/1 Head, Subsurface Engineering 42
43 PTS/2 Head, Surface Engineering 43
44 PTS/3 Head, Specialist Maintenance 44
45 PTS/4 Head, Quality Control 45
46 PTS/5 Head, Inform. Technology 46
47 PTS/6 Head, Production Measurement 47
48 POD Manager, Duyong 48
49 POD/1 Head, Operations 49
50 POD/2 Head, Asset Planning 50
51 POL Manager, Dulang 51
52 POL/1 Head, Operations 52
53 POL/2 Head, Asset Planning 53
54 POP Manager, PM9 Operations 54
55 POP/1 Head, Operations 55
56 POP/2 Head, Asset Planning 56
57 PPL Manager, Planning 57
58 PMO Lib. PMO Library 58
59 OTHERS COO Chief Operating Officer 59
60 SCD Manager, Strategy & Cap. Dev. 60
61 OTHERS P-PO01 HIT - Corrosion Management 61
62 B-PO05 HIT - Operation Philosophy 62
63 B-PO07 HIT - Maint. Control System 63
64 B-PO08 HIT - Pipeline Freespans 64
65 D-PO09 HIT - Underwater Maintenance 65
66 B-PO10 HIT - Topsides Maintenance 66
67 S-PO13 HIT - Painting Practices 67
Page iv
AMENDMENT SUMMARY
This sheet must be completed in detail at each revision once this document has been approved.
Details must include revision number, description and indication of which pages and paragraphs have been
revised, date of revision approval, approvers title and signature.
Revision No. Date Description Approved by:
0 25/04/97 Original issue COO
Doc. Rev. Page No. Date Approved Remarks

No. by:
0 Main Table of July 1998 COO Addition of CIMG Implementation

Content, Page 02 Guide as Appendix VII.
0 Section 2 Page 04. July 1998 COO Addition of CIMG Implementation

Guide as Appendix VII.
Notes: (1) Document Holders to update Amendment Record as and when amendments/new revisions are
received.
(2) For description of amendment the Document Holder should indicate correction, modification,
update or deletion issue.
(3) Document Holder to enter their company reference number, sign and date the record of entry.
(4) Where part amendments are issued, the relevant page(s) will be identified with a lower case
letter in the revision status line in the header.
Page v
PREFACE
The PCSB Inspection and Maintenance Guidelines (CIMG) is a document providing a

standard set of guideline for the implementation of inspection and maintenance programme
for PCSB production facilities and their associated equipment. These guidelines reflect the
practices of the Company as given in the Production Operations Philosophy document as
well as the Corrosion Management System Manual.
The Production Sharing Contract (PSC) with PETRONAS requires PCSB to have a
documented Inspection and Maintenance practices / guidelines. This CIMG is thus
developed based on the provisions of PETRONAS Guidelines for the Inspection and
Maintenance of Production Facilities (PGIM) dated February 1987, issued under Section
4.5 of the Procedures for Production Operations (PPO) Rev. 1 1988.
The usage of this document is expected to reduce the overall costs for inspection and
maintenance through the standardisation and optimisation of the various practices
throughout the regions. The document also provides the basis for a new and more rational
approach by implementing condition based concept on inspection and maintenance
activities.
This is a controlled document and to be revised and updated as changes in regulations or

PETRONAS requirements, revisions to the referred documents, feedback from end users
and other influencing circumstances dictate.
All requirements and guidelines stipulated in this CIMG document shall, as much as
possible, be adhered to by all parties concerned.
Thank you.
MOHAMAD JOHARI DASRI

GENERAL MANAGER
SARAWAK OPERATION
Page vi
Abbreviations and Acronyms
The following are frequently used abbreviations in this document and they shall be deemed to have the
following meaning:
ABS American Bureau of Shipping

AHT Anchor Handling Tug
ANSI American National Standards Institute
API American Petroleum Institute
ATPs Acceptance Test Procedures
CALM Catenary Anchor Leg Mooring
CBM Condition Based Monitoring
CCM Corrosion Condition Monitoring
CDBM Corrosion Design Basis Memorandum
CIMG PCSB Inspection and Maintenance Guidelines
CMS Corrosion Management System
DNV Det Norske Veritas
DOSH Department of Occupational Safety and Health. Formerly known as Factory
and Machinery Department (FMD).
FDP Field Development Plan
FSO Floating Storage & Offloading
HIT Hijrah Initiative Team
KPI Key Performance Indicators
IMP Inspection and Maintenance Philosophy
MCS Maintenance Control System (see also TRIDENT MCS)
MAWP Maximum Allowable Working Pressure
MEM Materials Engineering Memorandum
MOL Main Oil Line
MPI Magnetic Particle Inspection
MSL Mean Sea Level
NDT Non Destructive Testing
OCIMF Oil Company International Marine Forum
PLC Programmable Logic Control
PLEM Pipeline End Manifold
PGIM PETRONAS Guideline for Inspection and Maintenance
PMO Peninsular Malaysia Operations
POP Production Operation Philosophy
PPO PETRONAS Procedure for Production Operation
PPM Planned Preventive Maintenance
PRD Pressure Relief Devices
PTS PETRONAS Technical Standards
RBM Reliability Based Maintenance
RCM Reliability Centred Maintenance
ROV Remotely Operated Vehicle
Page vii
RT Radiographic Testing
SBO Sabah Operations
SBM Single Buoy Mooring
SCSSV Surface Control Subsurface Safety Valve
SKO Sarawak Operations
SOLAS Safety of Life At Sea
SPM Single Point Mooring
SPT Single Point Turret
SRB Sulphate Reducing Bacteria
SSPC Steel Structure Painting Council
SSS Side Scan Sonar
SWL Safe Working Load
UT Ultrasonic Testing
UWILD Underwater Inspection In Lieu of Dry-docking
VSWR Voltage Standing Wave Ratio
The following terms are used in this document and they shall be defined as the following:
Abselling A method for access using rope also known as Roped Access. Suitable for
carrying out inspection and minor repair and maintenance works.
Asset Anything that has value to the company but in the context of the Asset
Management it is considered as the sum of the valuables within the
designated asset, that creates value for the company.
Asset Holder The position which is accorded single point accountability for all aspects of
the management of a clearly defined asset or group of assets.
Business Units A single regional operation such as Sarawak Operations (SKO), Sabah
Operations (SBO) and Peninsular Malaysia Operations (PMO) in the PCSB
Production Division.
Company PETRONAS PCSB Sdn. Bhd.
Competent Person A person appointed, in writing, by the head of the user department who has
successfully completed a Company approved rigging and slinging course
and who is considered competent by virtue of training and experience to
inspect wire rope, slings and other lifting tackle for signs of deterioration
and other defects and to assess what effect the said deterioration or
defects will have on the strength and function of the lifting tackle.
Condition Based The basis for maintenance, whereby the item's condition is monitored,
Maintenance utilising measurements such as corrosion rate, wall thickness, lubricating oil
status, vibration levels etc. This is done so that failures can be identified
and maintenance requirements can be predicted in advance.
Corrosion The deterioration of a material , usually a metal and its alloys by reaction
with its environment. In oil and gas production operations, the reactions are
primarily electrochemical.
Page viii
Electrical Installation All equipment items related to power generation, distribution and / or
utilisation.
Export Facilities Floating Storage & Offloading (FSO) Vessel, Single Point Moorings (SPM)
System consisting of Single Buoy Mooring (SBM) and Single Point Turret
(SPT), the associated cargo hoses and mooring buoy.
Fluid Any gas or liquid
Inspection Visual assessment, data gathering, measurement, testing and analysis to

determine the condition of an item.
Visual assessment, testing and measurement to evaluate workmanship or

quality of completed work for acceptance based on an agreed specification.
The output is normally an inspection report which include description of
anomalies, defects found and remedial action, if any, to retain it in, or
restore it into, a state where it can perform its required duty.
Maintenance Execution of all activities identified during inspection to retain, restore or

replace an item into a state where it can perform its required duty.
Major Rotating Equipment Equipment such as gas turbines, internal combustion engines,
compressors (reciprocating / centrifugal), crude oil transfer pumps,
firewater pumps and other equipment of similar nature.
Offshore structures Include all steel structures installed offshore which support production
facilities, compression facilities, living quarters, wellheads, vent stacks and
all other topsides of related function.
Production Operations A document providing guidance to all Business Units within the Production
Philosophy Division of PETRONAS PCSB Sdn. Bhd. on managing their activities in the
production of hydrocarbons utilising common and standard methodology.
Pipelines All subsea and onshore pipelines (e.g. trunklines, interfield lines, risers)
which carry either hydrocarbons, water or any other fluids associated with
the production or transportation of hydrocarbons from one location to
another as covered by the ANSI-ASME 31.4 and 31.8 codes.
Pressure Relieving Pressure relief valves and any other device of similar nature and function.
Devices
Pressure Vessels Enclosed vessels under pressure greater than atmospheric pressure by any
liquid or gas or mixture or combination. They include process vessels,
storage drums, sumps, blowdown tanks, separators, contactor towers,
compressors suction and discharge pulsation bottles, pulsation dampeners,
knockout pots, columns, heat exchangers, gas cylinders, and air receivers.
Reliability Based Application of investigative and correct technology towards solving the root
Maintenance cause of any machinery problem. This RBM approach shall only be
(a.k.a Proactive applicable in upgrading and designing out any recurring problems, so as to
Maintenance) improve machinery reliability.
Reliability Centred A structured procedure to optimise expenditures by evaluating maintenance

Maintenance strategies based on operational functions of a process, and its failure
modes and consequences. The output shall identify the appropriate
maintenance strategies to be applied to the particular equipment.
Page ix
Surface Main Facilities Includes process piping, flowlines or headers, pressure vessels, steam
boilers, major rotating equipment, cranes and lifting equipment, storage
tanks, export and support facilities.
Subsurface Main Facilities Includes subsea wellheads, wellheads and X-mas tree, production tubing
and downhole subsurface safety valves.
Safety Devices and Include all active or passive devices and / or systems which are designed to
Systems warn or provide protection to personnel, equipment and the environment.
Splash Zone That section of an offshore structure, riser and/or subsea conductor lying in
the range of 3 metres (10 feet) below to 3 meters above mean sea level.
Storage Tank Tanks or vessels including atmospheric and low pressure tanks / vessels
used for storage and subsequent handling of petroleum or petroleum
products.
Surface X-mas tree and All master valves, crown valves, safety valves and flowline valves located a
assemblies the wellhead.
Telecommunication Include auxiliary radio systems, switching equipment, PETRONAS Wide

Facilities Area Network (PETRONET), microwave & satellite systems, public
address systems, alarm systems and telecommunication towers.
Instrumentation and Include pressure / temperature / flow / level switches, transmitter, controller,
Control System regulator, recorder, indicator, gauges.
Inspection Data Analysis A computerised system to assist inspection and corrosion engineers in
and Management System PCSB to plan, control and manage inspection and corrosion monitoring
(IDAMS) programme.
TRIDENT MCS A computerised Maintenance Control System for planning, control and
recording maintenance activities of PCSB assets.
Page x
Referenced Documents
Page xi
Introduction Rev. 1 December 2000
Section 1
INTRODUCTION
Contents
Paragraph Page
1 BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 SCOPE AND LAYOUT ............................................... 3
4 INSPECTION AND MAINTENANCE STRATEGY . . . . . . . . . . . . . . . . . . . . . . . . 4
5 IMPLEMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PETRONAS CARIGALI SDN BHD SECTION 1
Page 1
1 BACKGROUND
This document shall be known as the 'Carigali Inspection and Maintenance Guidelines'
(CIMG). It provides a standard set of guidelines for the implementation of inspection and
maintenance programme for Carigali production facilities and their associated equipment.
These guidelines reflect the practices of the Company as given in the Production
Operations Philosophy document and Corrosion Management System Manual.
The Production Sharing Contract (PSC) with PETRONAS requires Carigali to have a
documented Inspection and Maintenance practices / guidelines. This CIMG is thus
developed based on the provisions of PETRONAS Guidelines for the Inspection and
Maintenance of Production Facilities (PGIM) dated February 1987, issued under Section
4.5 of the Procedures for Production Operations (PPO) Rev. 1 1988.
Prior to this issue each Carigali Production Division has its own Inspection and
Maintenance Philosophy (IMP) document to meet the above PSC requirement with
PETRONAS. During the 1995 Organisational Effectiveness Studies (OES) an opportunity
to reduce inspection and maintenance costs was identified through the standardisation of
the various IMPs into a single Carigali document. Subsequently a Hijrah Initiative Team
(HIT B-PO06) was appointed by Carigali management to review current Inspection and
Maintenance (IM) practices and analyse the needs for a more rational approach and
alternatives.
This CIMG as a deliverable of the HIT, finally presents the basis for a new and more
rational approach to inspection and maintenance during production operations. Feedback
from stakeholders within Carigali was solicited and subsequently concurrence from
PETRONAS was sought prior to finalising of this document.
2 OBJECTIVES
The objectives of this CIMG are:
To provide consistent, efficient and cost effective IM practices across all Business
Units in Carigali Production Division.
To provide optimum levels of inspection and maintenance for preserving the long
term fitness-for-purpose of the facilities and equipment.
To promote the application of Reliability Based Maintenance (RBM) and Condition

Based Maintenance (CBM) concepts to inspection and maintenance activities.
To improve effectiveness in IM planning and performance assessment.
These objectives, while based on sound economic principles shall be achieved with due
regard to safety, environment and Malaysian Laws and Regulations. Determination of the
acceptability or otherwise of committed levels of inspection and maintenance efforts shall,
in general, be measured through the application of the agreed Key Performance Indicators
(KPIs).
Page 2
3 SCOPE AND LAYOUT
This CIMG covers the inspection and maintenance of Carigali production facilities and
associated equipment world-wide. It is based on the experience gained in existing
Business Units of Carigali Production Divisions namely Sarawak Operations (SKO),
Peninsular Malaysia Operations (PMO) and Sabah Operations (SBO). This CIMG shall
also be applicable abroad where type of facilities and / or equipment, mode of operations
are similar and where the stipulated IM practices do not contravene host-government
statutory laws and regulations.
The body of this CIMG is divided into the following sections:
(1) Offshore Structures
(2) Pipelines and Risers
(3) Piping and Flowlines
(4) Pressure Vessels and Steam Boilers
(5) Major Rotating Equipment
(6) Storage Tanks
(7) Cranes and Lifting Equipment
(8) Export and Support Facilities
(9) Subsurface Main Facilities
(10) Safety Devices and Systems
(11) Instrumentation and Control Systems
(12) Electrical Equipment and Installations
(13) Telecommunication Facilities
Each of the above-mentioned section is presented in accordance with the typical

sequence of Inspection and Maintenance activities i.e.
Extent of Coverage
References and Guidelines
Inspection and Maintenance Plan
Inspection Scope and Frequency
Assessment and Recommendation
Page 3
Maintenance
Documentation
4 INSPECTION AND MAINTENANCE STRATEGY
The following strategy is adopted for inspection and maintenance of all Carigali's
production facilities and associated equipment:
The period between inspections is determined on the basis of statutory requirement,

reliability of design, exposure to risks, previous inspection results and analysis.
Execution of inspection is done on a timely manner utilising efficient and

cost-effective techniques
The scope of maintenance is planned and executed to be conditional upon the

findings of inspections and condition monitoring activities.
Essential inspection and maintenance data are consistently and timely gathered,
analysed and trended using suitable software for use in determining course of action.
To use advances in technology in inspection and maintenance to Carigali's

advantage. This includes abseiling for access during inspection, utilisation of
computerised data bases for managing IM information, inspection techniques and
condition assessment techniques.
Optimisation utilisation of available resources through better planning and execution

of IM activities.
In determining the scope and frequencies of inspection and maintenance of the production
facilities and equipment the following factors shall be taken into consideration:
(a) Statutory Requirements
Requirements set by local or Malaysian law governing the installation and

operation of the facilities.
(b) Design Factors
Robustness of the facility design
Availability of standby unit or back-ups
Reliability of the installed facilities
(c) Operational Factors
The extent of usage and criticality of the facility towards achieving the desired
production availability.
Page 4
(d) Risk Factors
Exposure to risks which results in loss of people, property, process or damaging

impact to the environment .
(e) Condition Factors
Latest inspection findings and data analysis results
Latest maintenance records
In the event that the provisions of this CIMG are found not applicable to a specific item of
equipment in a given situation, then the inspection and maintenance practices in terms of
scope and frequency for the said equipment shall be derived on the basis of applicable
Malaysian Laws and Regulations, internationally recognised Codes and Standards,
manufacturers' recommendations and sound oil industry practices.
5 IMPLEMENTATION
Responsibilities for implementing the IM practices stipulated in this CIMG have been
assigned on a departmental basis and are identified within the content of the document.
Review for compliance shall be carried out by each department on a periodical basis.
Properly planned and executed inspection and maintenance is a fundamental requirement

for preserving the integrity of Carigali's production facilities. It facilitates determination,
monitoring and control of equipment's fitness-for-purpose both at the detailed item level
and at overall facility level. The rate and type as well as possible consequences of
equipment deterioration or failure are all significant in defining the desired scope of work
and frequency of planned inspection and maintenance activities. The said deterioration
may take many forms and may be a function of various factors including design criteria,
specification and details, fabrication standards and quality control, in-situ conditions and
functional utilisation.
Clear and concise documentation of completed inspection and maintenance together with
rigorous analysis of significant findings constitutes an essential element of this CIMG. It is
vital in providing a basis upon which timely planning and decision making can take place
with respect to the needs, or otherwise for remedial / corrective actions. This in turn
promotes wholly controlled operation of production facilities with due regard to safety,
environment and applicable Malaysian Laws and Regulations.
It is recognised however that similar equipment placed in differing operational or

environmental situations or, items of similar generic set but of different technical
specification and/or, any equipment which undergoes a change in its condition of service ,
might warrant variations in scope and frequency from the general provisions of this CIMG.
Such variations are acceptable provided always that they can be justified on technical and
commercial grounds to the responsible party.
These variations will typically be based upon a confluence of accumulated experience

together with rigorous analysis of available information such as equipment inspection,
maintenance and functional history, review of current and intended operating
circumstances and where available relevant performance condition monitoring results by
means of suitable computer databases.
Page 5
Document Revision Control Rev. 1 December 2000
Section 2
DOCUMENT REVISION CONTROL
Contents
Illustrations
Figure Page
2.1 Document Control Process Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Page 1
The Carigali Inspection and Maintenance Guidelines is a controlled document where all
copies are numbered and holders are registered and updated on any revisions made.
Controlled copies of the CIMG are distributed as per the distribution list in this document.
The overall control of the CIMG is the responsibility of the appointed Custodian i.e.
Sarawak Operations (SKO) General Manager. The custodian is responsible for the
maintenance and updating of the CIMG document.
The CIMG is reviewed, as a minimum, annually during the Management Review and all
revisions, where necessary, shall be agreed by the CIMG Technical Committee and
endorsed by the Chief Operating Officer (COO).
The revision to the guidelines may result from:
(a) Changes in regulation or PETRONAS requirements.
(b) Revisions to documents referenced by the guidelines.
(c) Inputs from users, based on feedback from projects, line or operational experience.
The users may transmit the proposed changes or amendments to the Custodian who will
co-ordinate the review process and approval. The steps are detailed in below and in the
flowchart on the following page.
(i) The originator may be any individual staff who recognises the need for change and
submit request for change to the custodian using the provided CIMG Change
Proposal Form - see Appendix VI.
(ii) The Custodian will select Subject Matter Expert (SME) who will review the proposal
together with the originator and, if necessary, prepare the draft of revised section of
the guidelines.
(iii) The Custodian shall issue the draft revision to the process owners for review and
comments.
(iv) Upon receiving comments from the process owners, the custodian shall distribute the
comments to committee members and at the same time notifying the latter of the
dates of the Co-ordination meeting.
(v) The committee shall discuss and decide on the acceptance of the issues.
(vi) Upon agreement and approval by the committee, the custodian shall revise the
document, where applicable, and seek endorsement from COO prior to distribution of
the relevant changes to all users as per distribution list.
(vii) Should the proposed changes are NOT considered acceptable by the committee
and/or COO, the originator will be advised accordingly and may be requested to
revisit the proposal and provide further justifications.
(viii) The originator shall then repeat the cycle above.
Page 2
ORIGINATOR CUSTODIAN SME COMMITEE PROCESS OWNERS
Start
Identify/Propose
Changes
Review & Prepare Draft Review / Comment
Distribute Comments
to Committee members
Coordination meeting
Revise & N Approve

Re-justify? Inform Originator Changes?
Y**
N
Revise Document
Close
Distribute to Users
Notes:
Notes :
All approved changes are to be
End
All approved
endorsed by COOchanges are to
SME denotes for
be endorsed by Subject
COO.Matter
Expert.
SME denotes for Subject
Matter Expert.
Figure 2.1 Document Control Process Flow
Page 3
Offshore Structures Rev. 1 December 2000
Section 3
OFFSHORE STRUCTURES
Contents
Paragraph Page
1 EXTENT OF COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 REFERENCES AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 INSPECTION AND MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 INSPECTION SCOPES AND FREQUENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Installation Acceptance Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Benchmark Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.3 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.4 Periodic Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4.1 Above mean sea level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4.1.1 Painting / coating survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4.1.2 Intermediate survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4.1.3 Major (workscoping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4.2 Splash zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4.2.1 General survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4.3 Below mean sea level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4.3.1 Intermediate survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4.3.2 Major survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 ASSESSMENT AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1 Above Mean Sea Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1.1 Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1.2 Intermediate maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1.3 Major maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.2 Splash Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.2.1 Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.3 Below Mean Sea Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3.1 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Page 1
Item Description Responsible

No. parties
1 EXTENT OF COVERAGE
This section specifies the inspection and maintenance guidelines of
offshore structures accommodating Carigali's production facilities. It
defines the nominal scopes and frequencies for condition-based
inspection and maintenance to ensure acceptable reliability and
technical integrity by timely detection of deterioration and remedial
actions. Responsible parties are also identified for each activity.
Deviation from this guideline shall be documented in detail and shall
require Carigali management endorsement and PETRONAS
concurrence.
2 REFERENCES AND GUIDELINES

The following are the references and guidelines for this particular
section:
API RP2A - Recommended Practice for Planning, Designing and

Constructing of Fixed Offshore Platforms latest edition.
Lloyds Register of Shipping Guidelines.
UK D.O.E Regulations.
DNV Rules for Offshore Structures.
SSPC Guide.
IP Code.
ANSI / ASME Codes.
AWS D1.1 Structural Welding Codes.
3 INSPECTION AND MAINTENANCE PLAN

A rolling Inspection and Maintenance plan which suits the design basis Technical
and operating life of the structures shall be formulated and made Services
available. This plan shall cover: Short term: annual look ahead in detail.
Long term: a period of 15 years or up to the end of structure design / DDE
economic life, whichever comes first. The updates shall take into
consideration all previous relevant inspection data and analysis results.
The plan shall be updated on an annual basis.
Page 2
Item Description Responsible

No. parties
4 INSPECTION SCOPES AND FREQUENCIES
4.1 Installation Acceptance Survey
Scope: As a minimum the survey shall include the following: A visual Technical
inspection of the entire structure (topside and substructure) to detect Services
damage or anomalies from the construction and installation phases and
sea bed debris. As-built condition surveys NDTs as and when DCE
necessary Upon satisfactory findings from the survey an Installation
Acceptance Certificate shall be released. DDE
Frequency: This inspection shall be carried out prior to hand over of

the structures to Carigali, and departure of Installation Contractor from
site.
4.2 Benchmark Survey
This survey also referred to as the Baseline Survey where the Technical
information gathered will serve as a basis for comparison during future Services
surveys. As a minimum the survey shall include the following: Visual
assessment of the entire structure including its appurtenances. NDT on DDE
selected key structural members and nodes. Verify overall
configurations of structural members against as-built drawings. Check
for damage, corrosion, anomalies, anode depletion, scour, debris,
marine growth and conditions of riser clamps. Assessment of coating
deterioration on entire surface to determine need for touch up painting
or total re-coat.
Frequency: The survey shall be carried out within one year of

Installation Acceptance, or completion of drilling program, if applicable.
The Benchmark Survey can be waived if the entire scope has been
covered in the Installation Acceptance Survey.
4.3 Special Survey
Scope: A visual assessment shall be conducted to determine physical Technical

damage from reported collisions, changes in loading, major Services
modifications, after major storms or suspected subsidence. The extent
of inspection must be based on rigorous appraisal of available data. DDE
Frequency: This inspection shall be conducted when required, based

on the severity of each respective incident or situation change or as
determined by the results of detailed structural re-analysis.
Page 3
4.4 Periodic Survey
4.4.1 Above mean sea level
4.4.1.1 Painting / coating survey
Scope: As a minimum the survey shall include the following: A detailed

visual survey of overall structure to detect any painting damage and to Technical
ensure that the paintings are in good condition. Numerous structural Services
elements (e.g., support beams, connections, edges) shall be rated
separately and combined to provide an overall structure or facility
rating. Record of several condition parameters (e.g., loss of topcoat,
cracking, rust staining), and several corrosion parameter (e.g., rusting,
scaling, blistering, loss of metal). For detailed rating of structural
elements, refer to Carigali Painting Practices Manual.
Frequency: This inspection shall be carried out within 6-12 months

after first application in order to detect possible failure caused by
improper preparation and / or application, and subsequently at yearly
intervals.
4.4.1.2 Intermediate survey
Scope: As a minimum the survey shall include the following: A detailed

visual survey of selected structural members to detect damage or Technical
anomalies. NDTs where and when identified as necessary following Services
the visual inspection.
Intermediate Survey A physical coating inspection of the entire

structure and the external surface of equipment shall be carried out to Technical
check for corrosion and coating deterioration and, therefore, determine Services
the need for repair or re-coating.
Frequency: This inspection shall be carried out in between (but not

exceeding 2-1/2 years from) Major (Workscoping) Surveys.
4.4.1.3 Major (workscoping)
Survey Scope: All required work for the next Major Maintenance shall Technical
be defined and detailed from this survey. This survey shall include: Services
Visual assessment on the condition of the entire structure. NDT on
selected structural members to determine overall condition and
configurations inspection of coating on entire structure and external
surfaces of equipment for corrosion and coating deterioration, to
determine the extent of repair or re-coating required.
Frequency: This survey shall be conducted every five years but this
schedule may be altered if justified due to actual found conditions. This
survey must be strategically planned and carried out prior to the Major
Maintenance visit. This is to allow ample time for preparatory works
(design, work packing, contracting out, procurement). However, it
should normally be carried out not more than one year from the Major
Maintenance visit.
Page 4
4.4.2 Splash zone
4.4.2.1 General survey
Scope: As a minimum the survey shall include the following: Close Technical
visual inspection at selected locations to check for mechanical damage, Services
debris, marine growth and coating conditions. CP readings. NDT on
selected areas or joints to determine integrity. This is be carried out DDE
during the lowest tide to avoid the need for divers where possible.
Frequency: This survey shall be carried out every 2 1/2 years and shall
be integrated with the Intermediate and Major Surveys for Above and
Below Mean Sea Levels.
4.4.3 Below mean sea level
4.4.3.1 Intermediate survey
Scope: The survey shall only cover critical areas of structure found to Technical
require closer monitoring based on previous survey and analysis. Services
Frequency : This survey, if required, shall be carried out in between DDE

Benchmark and / or Major Surveys.
4.4.3.2 Major survey
Scope: The above survey covers a more comprehensive area and shall Technical
include the following: A visual inspection to determine overall condition. Services
DDE
Major Survey Verifications of structural configuration against as-built
drawings. Flooded member detection (optional). Tie-in butt weld Technical
inspection by visual supplemented with NDT if necessary. Check for Services
damage, corrosion, anomalies, riser clamp conditions, anode depletion
(to determine remaining anode life), scour, debris and marine growth. DDE
NDT on selected key structural members and nodes (as for Section
5.1.4.2, Benchmark Survey). Structures susceptible to subsidence shall
be surveyed and analysed to determine proposed action as required.
Frequency : This survey shall be conducted every five years but this
schedule may be altered if justified due to actual conditions.
5 ASSESSMENT AND RECOMMENDATIONS
Inspection reports complete with recommendations for remedial actions

where appropriate shall be issued within three months of inspection Technical
completion to relevant parties for assessment. Timely review and Services
assessment of inspection data shall be carried out by the identified
parties. Recommendations for remedial actions shall be based on DDE
criticality of the anomaly, detected defects and the remaining design /
economic life of the structure. Trends from sequential data following
remedial actions shall be monitored for future inspection plans.
Page 5
6 MAINTENANCE
6.1 Above Mean Sea Level
6.1.1 Routine maintenance
Scope: Routine maintenance a.k.a First Line Maintenance shall be

planned and carried out for any item during daily operations upon its Assets
identification. It shall include repair of localised coating damage and
minor rectification works.
Frequency: This maintenance is condition-based and should be

executed as soon as the required materials and resources are available
to prevent further deterioration.
6.1.2 Intermediate maintenance
Scope: The scope shall be limited to priority maintenance items

identified during previous survey or daily operations surveillance which Technical
cannot be left for the next Major Maintenance visit which include the Services
following: Touch up painting Repair or replacement of corroded
structural members e.g. handrails, stairs, gratings, etc.)
Frequency: Intermediate maintenance is condition based, to be

conducted in between Major Maintenance when required (but not
exceeding 2 1/2 years).
6.1.3 Major maintenance
Scope: The above shall be carried out, as identified from the Technical
workscoping survey, and following analyses / review by the responsible Services
parties. The scope shall include: Repair of primary and secondary
structural members. Replacement or repair of corrosion protection
coatings by blasting and painting. Replacement of corroded structural
components which cannot be salvaged by blasting and painting. The
decision to either full blast and paint or only spot blast and touch-up
paint shall be made following analysis of inspection recommendations,
considering the criticality and remaining design / economic life of the
structure.
Frequency: The maintenance schedule is based on intervals of five

years but this schedule may be altered if justified due to actual
conditions. It shall always be integrated with the Major Maintenance of
all other topsides disciplines.
6.2 Splash Zone
6.2.1 Corrective maintenance
Scope: The above maintenance shall be carried out for any item Technical
identified following the analysis of General Survey results (see Services
5.1.4.4.2.1). The scope shall include: Marine growth control and
cleaning if necessary. Repair or replacement of structural items e.g. DDE
boat landing, handrails, gratings, swing ropes, etc.
Page 6
Frequency: This maintenance is condition-based and, where Technical

appropriate, shall be integrated with the Above or Below Mean Sea Services
Level maintenance visits.
DDE
6.3 Below Mean Sea Level
6.3.1 Corrective Maintenance
Scope: Repair and remedial works identified following analysis of the Technical
results of any of the above Surveys (see Sections 5.1.4.4.3.1 and Services
5.1.4.4.3.2), taking into consideration the criticality and remaining
design / economic life of the structure. DDE
Frequency: This maintenance is condition-based, preferably to be

executed simultaneously with the above surveys, or any underwater
activities within the vicinity.
7 DOCUMENTATION
All inspection and maintenance activities shall be documented and Technical

continuously updated in a timely manner using a suitable database Services
such as IDAMS for storage, easy retrieval and analysis. Documentation
must be sufficiently detailed to enable meaningful integrity assessment DDE
and analysis to be carried out. This documentation shall be subjected to
annual review.
Page 7
Pipeline And Risers Rev. 1 December 2000
Section 4
PIPELINE AND RISERS
Contents
Paragraph Page
1 EXTENT OF COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 REFERENCES AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 INSPECTION AND MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 INSPECTION SCOPES AND FREQUENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 Installation Acceptance Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Start Up Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Benchmark Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.1 Subsea pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.2 Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3.3 Onshore buried pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3.4 Onshore - above ground pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Intelligent Pigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4.1 Gas lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4.2 Oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Internal Corrosion Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.7 Periodic Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.7.1 Subsea pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.7.1.1 Cathodic protection (CP) monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.7.1.2 Side scan sonar survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.7.1.3 Remotely-operated vehicle (ROV) survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7.1.4 Diver inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7.2 Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7.2.1 General survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7.2.3 Intermediate survey (above water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7.2.4 Ultrasonic wall thickness (UT) key point survey . . . . . . . . . . . . . . . . . . . . . . 13
4.7.2.5 Diver inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7.3 Onshore - buried pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7.3.1 General survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7.3.3 Major survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.7.4 Onshore - above ground pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7.4.1 General survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Page 1
4.7.4.2 Major survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 ASSESSMENT AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Subsea Pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4 Onshore - Buried Pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.5 Onshore - above ground pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Page 2
Responsible
Item No. Description
Parties
This section specifies the inspection and maintenance

guidelines for Carigali's pipelines and risers, including pig
launchers/receivers which transport products within Carigali's
production facilities. It defines the nominal scopes and
frequencies for condition-based inspection and maintenance
to ensure acceptable reliability and technical integrity. This is
achieved through the timely detection of deterioration and
remedial actions. Responsible parties are identified for each
activity.
Deviations from this guideline shall be documented in detail

and shall require Management endorsement and PETRONAS
concurrence.
The following are the references and guidelines for this

particular section:
Petroleum (Safety Measures) Act
Petroleum (Safety Measures) Regulations
ANSI/ASME B31.4 Oil Transmission Piping
ANSI/ASME B31.8 Gas Transmission and Distribution

System
ANSI/ASME B31.3 Chemical Plant and Petroleum

Refinery Piping.
DNV Rules for Submarine Pipelines
API RP 1111 Recommended Practices for Design,

Construction, Operation and Maintenance of Offshore
Hydrocarbon Pipelines
Page 3
Responsible
Parties
3 INSPECTION AND MAINTENANCE PLAN Technical
Services
A rolling Inspection and Maintenance Plan which suits the
design basis and operating life of the pipelines and risers shall DDE
be formulated and made available. This plan must cover:
Short term: annual look ahead in detail.
Long term: a period of 15 years or up to the end of

facilities design / economic life, whichever comes first.
The updates shall take into consideration all previous relevant

inspection data and analysis results. The plan shall be
updated on an annual basis.

4.1 Installation Acceptance Survey
Scope:
Technical
The above survey shall be carried out as follows: Services
External visual inspection. In the case of subsea DCE

pipelines this involves using ROV.
Right-of-way and as-built route surveys.
Check CP system.
Pipeline support (free span) check
Deliverables shall include as-built route drawings.
Frequency:
This survey shall be carried out prior to handover of the

pipelines to Carigali, and departure of Installation Contractor
from site.
Page 4
Responsible
Parties
4.2 Start Up Survey
Scope: Technical
This survey shall include the following: Services
Check status for safe operations. In the case of subsea DDE

pipelines this include seabed conditions and debris
survey.
Visual inspections of all mechanical couplings, clamps,

fittings, flanges and PLEM.
Frequency :
Before start-up. This survey can be waived if the entire scope
has been covered in the Installation Acceptance Survey and if
start-up is immediate.
4.3 Benchmark Survey
4.3.1 Subsea pipelines
Scope: Technical
A side scan sonar shall be carried out in combination with Services
visual inspection by ROV or diver on exposed pipelines to
check the following: DDE
right-of-way (crossings)
route and location
signs and extent of any corrosion
mechanical damage
coating holidays
Appurtenances
supports (freespans)
Debris
CP system
wall thickness at selected locations
Page 5
Responsible
Parties
Where ROV and diver are not used, possible corrosion or
damage may be assessed by monitoring the performance of
the CP system or coating conditions.
Frequency :
The survey is to be carried out within ` should be integrated
with Offshore Structures Benchmark Survey. This survey can
be waived if the entire scope has been covered during the
Installation Acceptance Survey.
4.3.2 Risers
Scope:
Technical
Visual inspection (by diver or ROV for subsea portion) of up to Services
50 metres from the platform to check for:
DDE
mechanical damage
coating holidays (where applicable)
Appurtenances
supports (freespans)
Debris
CP system
wall thickness at bends
Where ROV and diver are not used, possible corrosion or

Frequency :
The survey is to be carried out within one year of operation.

For new offshore facilities, it should be integrated with
Offshore Structures Benchmark Survey. This survey can be
waived if the entire scope has been covered during the
Installation Acceptance Survey.
Page 6
Responsible
Parties
4.3.3 Onshore buried pipelines
Scope:
Technical
Visual inspection to check pipeline: Services
right of way
route and location
damage coating holidays (at accessible areas)
CP systems (transformer-rectifier)
wall thickness (at accessible areas)
Where pipelines are inaccessible, possible corrosion or

Frequency :
The survey is to be conducted within one year of Installation

Acceptance. This survey can be waived if the entire scope has
been covered during the Installation Acceptance Survey.
4.3.4 Onshore - above ground pipelines
Scope: Technical
Services
Visual inspection to check pipeline:
right of way and crossings
mechanical damage
coating holidays
wall thickness at selected locations
NDT shall be conducted where signs of corrosion or

damage are present. Internal inspection shall be carried
out in selected key accessible areas.
Page 7
Responsible
Parties
Frequency: Technical
Services
The survey is to be conducted within one year of Installation
Acceptance.
The Benchmark Survey can be waived if the entire scope has

been covered during the Installation Acceptance Survey.
4.4 Intelligent Pigging

4.4.1 Gas lines
Scope:
Technical
Services
For major or trunk gas lines, inspection for corrosion and
erosion damage shall be conducted by utilising intelligent
pigging tools capable of measuring both internal and external
damage.
Frequency :
The surveys shall be conducted on selected pipelines at five

yearly intervals. This schedule, however, may be altered if
justified due to actual found conditions. For more details refer
to BDO Guidelines on Operational Pigging (custodian:
BTS/21) .
4.4.2 Oil lines
Scope:
Technical
For major or trunk oil lines, inspection for corrosion and Services
erosion damage shall be conducted by utilising intelligent
pigging tools capable of measuring both internal and external
damage.
Pipelines shall be selected for inspection once conditions

within indicate a potential corrosion problem eg. significant
water cut, high CO2 content in the dissolved gases or
excessive corrosion rates in the associated process plant.
Page 8
Responsible
Parties
Frequency :
Technical
The surveys shall be conducted on selected pipelines at five Services
yearly intervals. This schedule, however, may be altered if
justified due to actual found conditions. For more details refer
to BDO Guidelines on Operational Pigging (custodian:
BTS/21) .
4.5 Special Survey
Scope: Technical
Services
Internal and/or external inspections are to be conducted when
appropriate, where there are causes for concerns for safety,
stability or integrity arising from circumstances.
For internal inspections, calibrated corrosion survey tools and

instrument to be used on selected locations.
Frequency :
The survey shall be conducted, when required, following

analysis of available inspection data.
4.6 Internal Corrosion Monitoring
Scope: Technical
Services
The internal surfaces shall be monitored for corrosion and
erosion, utilising suitable methods such as: probes, weight
loss coupons, sampling, thickness gauging and monitoring
water chemistry (eg for iron counts), temperature, pressure
and flow rate.
Frequency:
The above shall be carried out in intervals not exceeding six

months. This schedule, however may be altered if justified due
to actual found conditions.
Page 9
Responsible
Parties
4.7 Periodic Survey
4.7.1 Subsea pipelines
4.7.1.1 Cathodic protection (CP) monitoring
Scope: Technical
For both impressed current and sacrificial anode systems, the Services
CP measurements shall be carried out at selected key
locations along the subsea pipelines. DDE
The anodes (for sacrificial anode systems) shall be inspected

to determine their depletion rate.
Frequency :
Anode inspection (for sacrificial anode systems only ) and the
CP measurements shall be conducted at five-yearly intervals.
This inspection should be integrated with any ROV Survey or
Diver Inspection in the vicinity (see 4.7.1.3 and 4.7.1.4)
4.7.1.2 Side scan sonar survey
Scope:
Technical
Check the pipeline for: Services
free span locations and lengths DDE
deformations (kinks)
anchor scars
seabed general conditions and features
crossings and associated support locations
rig spudcan prints (if applicable)
movements from previous known locations
Deliverables include scaled route drawings indicating water

depth at 50-metre intervals and locations in eastings and
northings.
Page 10
Responsible
Parties
Frequency :
Technical
The survey shall be conducted every 2 1/2 years, Services
scheduled in between (within 2 1/2 years from) ROV
survey or Diver Inspection. It shall also be conducted DDE
after major construction activities along the pipeline
route.
4.7.1.3 Remotely-operated vehicle (ROV) survey
Scope: Technical
Confirm free spans, damages, debris or other anomalies Services
found by the Side Scan Sonar Survey (see Section 4.7.1.2).
CP survey at selected key locations shall be incorporated. DDE
Frequency:
The survey shall be conducted every five years.
4.7.1.4 Diver inspection
Scope:
Technical
The inspection shall include the following: Services
Wall thickness measurements where corrosion is DDE

suspected.
Detailed inspection and NDT on selected locations of

pipeline where removal of marine growth or coating is
required.
Check the integrity of node welded joints.
CP measurements where ROV cannot access.
Frequency :
The Diver Inspection shall be carried out only when required,

in place of ROV Surveys (see Section 4.7.1.3).
Page 11
Responsible
Parties
4.7.2 Risers
Scope : Assets
Perform close visual inspection of the riser and its

appurtenances above mean sea level, especially at joints,
supports and bends.
Frequency :
The survey shall coincide with ESD checks (see 10.4.3) i.e.
monthly for gas lines and every three months for oil lines.
Scope: Technical
Services
For impressed current systems, the magnitude and flow
direction of the current and potentials shall be measured. DDE
For sacrificial anode systems closed potentials shall be

measured.
Frequency :
For impressed current systems, CP shall be monitored at

three monthly intervals.
For sacrificial anode systems, CP shall be monitored at six
monthly intervals.
4.7.2.3 Intermediate survey (above water)
Scope :
Technical
The above survey shall include the following: Services
Close visual inspection of the riser and its

appurtenances above mean sea level during the lowest
tide. Sections which shall be particularly inspected are
flanges, clamps, supports, splash zone coatings to
determine the extent of damage or corrosion, if any.
Page 12
Responsible
Parties
Photographs of defects/findings shall be taken for
permanent records.
Where corrosion is present, a wall thickness and pitting

survey shall be conducted. The affected areas shall be
mapped out and reported.
Frequency :
The above survey shall be conducted yearly, unless conditions

call for more frequent surveys.
However, for vent platforms' risers, where shutdown is

required, this inspection shall be carried out at less intervals
i.e. when opportunity arise but not exceeding 2 1/2 yearly.
4.7.2.4 Ultrasonic wall thickness (UT) key point survey
Scope :
Perform close visual inspection and take ultrasonic wall Technical
thickness measurements at selected key locations (such as at Services
bends, joints and contact points) to enable the assessment of
the overall condition of the riser. DDE
Frequency :
The survey shall be conducted annually for the riser section
which is above mean sea level.
It shall be conducted every five years for the riser section

which is below mean sea level. This should be integrated with
Diver Inspection. (see 4.7.2.5) and / or Immediate Survey (see
4.7.2.3).
4.7.2.5 Diver inspection
Scope : Technical
Services
The inspection shall include the following:
DDE
Wall thickness measurements at 3, 6 and 9 o'clock
positions where corrosion is suspected.
Page 13
Responsible
Parties
Diver inspection
Detailed inspection and NDT of riser where removal of Technical

marine growth or coating is required. Services
Check the integrity of connections. DDE
CP measurements at the subsea bend and at the first

subsea clamp level.
Frequency :
The Diver Inspection shall be carried out every five years. It
should be integrated with any Subsea Survey of Offshore
Structures and Subsea Pipelines in the vicinity.
4.7.3 Onshore - buried pipelines

Scope: Assets
As a minimum the survey shall include a visual inspection to
check:
Right-of-way
Markers
Extent of vegetation
Human activities
Frequency:
The General Survey shall be conducted monthly.
Scope : Technical
Services
For impressed current systems, the magnitude and flow
direction of the current and potentials shall be measured.
Page 14
Responsible
Parties
Cathodic protection (CP) monitoring
For sacrificial anode systems closed potentials shall be Technical

measured. Services
Frequency :
For impressed current systems, CP shall be monitored at

three monthly intervals.
For sacrificial anode systems, CP shall be monitored at six
monthly intervals.
Scope: Technical
Services
check:
right-of-way (crossings)
signs and extent of coating damage
mechanical damage
CP systems and anodes where accessible
internal inspections at key accessible locations
Inspection technique such as Pearson Test shall be

conducted to detect external coating defect on buried sections
of the pipeline.
Frequency:
The Major Survey shall be conducted every five years.
Page 15
Responsible
Parties
4.7.4 Onshore - above ground pipelines
Scope: Assets

check:
Supports
Markers
Mechanical damage
Coating damage and deterioration
Right-of-way (crossings)
Extent of vegetation
Human activities
Frequency:
The General Survey shall be conducted every three months

and more frequent where human activities are of concerned.
Scope: Technical
Services
In addition to the General Survey above the following are to be
carried out during this Major Survey:
Signs and extent of corrosion
NDT where corrosion or damage is present
Internal inspections at key accessible locations
Frequency:
The Major Survey shall be conducted every three years.
Page 16
Responsible
Parties
Inspection reports complete with recommendations for Technical
remedial actions where appropriate shall be accurate and Services
issued within three months of inspection to relevant parties for
assessment. DDE
Timely review and assessment of inspection data shall be

carried out by the identified parties.
Recommendations for remedial actions shall be based on

criticality of the anomaly, detected defects and the remaining
design / economic life of the facilities. The maximum allowable
working pressures (MAWP) shall also be taken into
consideration and may be recommended to be adjusted if
appropriate.
6 MAINTENANCE
6.1 Internal Cleaning
Scope:
Assets
To maintain high fluid transport efficiency, all existing pipelines
except vent lines shall be internally cleaned periodically, using
any reliable and suitable tools e.g. brush pig, magnetic pig,
etc. Refer to Operation Manual for details.
As such, Launching / Receiving facilities shall be installed for

all new pipeline installations.
Frequency:
The Internal Cleaning shall be conducted where possible and

when required, based on fluid property and design, with
operational and technical considerations in mind (refer API RP
1111). Initial guidelines are as follows:
Oil lines - One Monthly
Gas lines - Three Monthly
Page 17
Responsible
Parties
6.2 Subsea Pipelines
Scope:
Technical
Maintenance for subsea pipelines shall be conducted when Services
identified by any of the surveys/inspections (see 5.2.4)
following overall integrity analysis. Appropriate rectification DDE
such as removal of debris, and installation of grout bags or
anodes shall then be carried out. Detailed written repair
procedures approved by the responsible parties shall be
prepared and adhered to.
Frequency:
When required, the Subsea Maintenance should be

conducted prior to the departure of diving contractor from the
area.
If this is not possible, it shall be carried out in the next

mobilisation, which shall be scheduled taking into
consideration exposure risks and integrity requirements.
6.3 Risers
Scope:
Technical
Maintenance for risers shall be conducted when identified by Services
any of the surveys/inspections (see Section 5.2.4) following
overall integrity analysis. Appropriate rectification such as DDE
removal of debris, installation of clamps or anodes and
blasting and painting shall then be carried out. Detailed written
repair procedures approved by the responsible parties shall be
prepared and adhered to.
Frequency:
For the section below mean sea level, the maintenance should
be conducted prior to the departure of diving contractor from
the area. If this is not possible, it shall be carried out in the
next mobilisation, which shall be scheduled taking into
consideration exposure risks and integrity requirements.
Page 18
Responsible
Parties
Risers
For the section above mean sea level, the maintenance shall Technical
be planned immediately and carried out as soon as feasible. It Services
should be integrated with the Major Maintenance of all other
disciplines, where possible. DDE
6.4 Onshore - Buried Pipelines
Scope: Technical
Services
Maintenance for onshore buried pipelines shall be conducted
when identified by any of the surveys/inspections (see 5.2.4)
following overall integrity analysis. Appropriate rectification
such as removal of debris, vegetation and installation of
clamps or anodes shall then be carried out.
Detailed written repair procedures approved by the

responsible parties shall be prepared and adhered to.
Frequency:
The maintenance shall be planned immediately and

conducted as soon as feasible.
6.5 Onshore - above ground pipelines
Scope: Technical
Services
Maintenance for onshore above ground pipelines shall be
conducted when identified by any of the surveys/inspections
(see 5.2.4) following overall integrity analysis. Appropriate
rectification such as removal of debris, vegetation, installation
of supports and blasting and painting shall then be carried out.
Detailed written repair procedures approved by the
responsible parties shall be prepared and adhered to.
Frequency:
The maintenance shall be planned immediately and

conducted as soon as feasible.
Page 19
Responsible
Parties
7 DOCUMENTATION
Technical
All inspection and maintenance activities shall be documented Services
and continuously updated in a timely manner using a suitable
database such as IDAMS and PIPEGIS (Pipelines DDE
Geographical Information System). This is to ensure proper
data storage, easy retrieval and for future trending and
analysis.
Any reports and/or documentation must be sufficiently detailed

to enable meaningful integrity assessment and analysis to be
carried out. This documentation shall be subjected to annual
review.
Page 20
Responsible
Parties
Page 21
Piping Flowlines Rev. 1 December 2000
Section 5
PIPING AND FLOWLINES
Content
Paragraph Page
1 PIPING AND FLOWLINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Extent of Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 References and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Piping Grading Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Inspection and Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Inspection ScopeS and Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.1 Pre-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.2 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.3 In-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.4 Out-of-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.5 Workscoping survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5.6 Internal corrosion / erosion monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Assessments and Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7.1 Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7.2 Intermediate maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7.3 Major maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Page 1
1 PIPING AND FLOWLINES
1.1 Extent of Coverage
This document summarises the Inspection and Maintenance guidelines for pipings,
flowlines and all the other associated valves and fittings/supports. It defines the nominal
inspection intervals and outlines the scope for monitoring the condition in comparison with
the design premises, besides including the application of condition-based maintenance.
Deviation from this guideline shall be documented in detail and shall require Carigali
management endorsement and PETRONAS concurrence.
1.2 References and Guidelines
The following shall serve as references and guidelines for this particular section: API 570
Piping Inspection Code - Inspection, Repair, Alteration and Reinstating of In-Service
Piping Systems. API RP 574 Inspection of Piping, Tubing, valves and Fittings ANSI/ASME
B31.3 Chemical Plant and Petroleum Refinery Piping Corrosion Management System.
1.3 Piping Grading Selection
The selection of appropriate grading shall be made based on several criteria, i.e. process
environment, age and condition, materials, considerations, corrosion/erosion, construction
details, etc. The gradings are as follows: Grade 1 - high CO2 and/or H2S contents, drain
systems containing corrosive fluids, oil lines containing free water. Grade 2 - fire fighting,
dry gas and vent systems. Grade 3 - sea water intakes, instrument air lines. The grading
shall be carried out during the design stage based on Field Development Plan (FDP),
Corrosion Design Basis Memorandum (CDBM) and Materials Engineering Memorandum
(MEM). The available data shall be reviewed if the relevant criteria changes.
Technical Services
1.4 Inspection and Maintenance Plan
An Inspection and Maintenance Plan which suits the design basis and operating life, shall
be formulated and made available. This plan shall cover : Short term. (This will involve an
annual look ahead in detail) and Long term. (This will cover a period of 15 years or up to
the end of the facilities design life, whichever is shorter) It shall also take into consideration
all previous relevant inspection data. The plan shall be updated on an annual basis.
Technical Services
Page 2
1.5 Inspection ScopeS and Frequencies
1.5.1 Pre-service inspection
Scope : As a minimum the above inspection shall cover: the external visual examination
supplemented by suitable NDT techniques limited visual internal examinations at pipe
extremities or flanged joints, and pressure tests in accordance with the design code, when
required. Frequency: This inspection shall be carried out before the piping is put into
service for the first time.
Technical Services
1.5.2 General inspection
Scope : The above inspection shall cover regular visual observations on the physical
conditions of the external piping. No specific checklists or inspection techniques are
required. Frequency : This inspection shall be carried out in conjunction with daily routine
operation activities.
Asset
1.5.3 In-service inspection
Scope : This inspection shall cover the following : an external visual examination and
coating survey of all piping / flowlines, including all associated hangars/supports, valves
and fittings, visual check for leaks. In-Service Inspection attention should be paid to small
bore piping connections where excessive vibration may lead to fatigue failure. NDT wall
thickness measurements shall be carried out, if necessary, for Grades 1 & 2 only. for
insulated pipings, CUI (Corrosion Under Insulation) shall be carried out. This may include
providing inspection windows at selected locations and through applicable techniques such
as flash radiography, neutron deep penetration, Eddy Current, etc. Frequency: This
inspection shall be carried out every 2 1/2 years and shall coincide with the Structural
Intermediate Survey (refer item no. 1.4.4.1.1).
Technical Services
1.5.4 Out-of-service inspection
Scope : This scope of this inspection shall include the visual and UT wall thickness for
areas not accessible during the on-stream inspection, as pre-determined by the
responsible party. Frequency: The inspection shall be carried out during shutdown
periods, as recommended by the responsible party.
Technical Services
Page 3
1.5.5 Workscoping survey
Scope : The Workscoping Survey shall define and detail all required works for the Major
Maintenance and as a minimum shall include: visual inspections of the entire pipings,
including the associated hangars and supports. NDTs on selected areas to determine
overall conditions. coating surveys for corrosion and coating deterioration to determine the
extent of repair or recoating required. Workscoping Survey Frequency : The survey shall
be conducted every five years, but may be changed if justified due to conditions. This
must be strategically carried out, prior to the Major Maintenance visit to allow ample time
for preparatory works (design, workpacking, contracting, procurement, etc.) but normally
no more than one year from the scheduled Major Maintenance. Wherever possible, the
survey shall coincide/integrate with the Structural Workscoping Survey (refer item no.
1.4.4.1.2).
Technical Services
1.5.6 Internal corrosion / erosion monitoring
The Internal Corrosion/Erosion Monitoring for selected piping shall be carried out using one
or more of the following: UT thickness measurements probes coupons Iron Counts
Sulphate Reducing Bacteria (SRB) Surveys piping assessment by spool piece examination
additional chemical analysis, eg. sulphide, sulphate, etc. Frequency: This
inspection/measurement shall be conducted every six months with the exception of: iron
counts - monthly SRB survey - monthly spool piece examination - annually
chemical analysis - monthly
Technical Services
1.6 Assessments and Recommendations
The results of the Internal Corrosion Monitoring shall be timely analysed and verified
against the findings from periodic and special inspections. Trends from sequential data
shall be monitored and utilised as a basis for future IM plans. Computerised Corrosion
Condition Monitoring system such as IDAMS CCM module can provide the necessary
functions to manage and analyse the gathered data.
Technical Services
1.7 Maintenance
1.7.1 Routine maintenance
Scope: The scope and extent of this maintenance shall be conditioned based and normally
include the repair of localised coating damage, touch-up painting and minor rectification
works. Frequency: Routine Maintenance shall be carried out when determine required
due to the as found condition.
Assets
Page 4
1.7.2 Intermediate maintenance
Scope : The scope and extent of this maintenance shall be limited to priority maintenance
items identified which cannot be left for the next Major Maintenance visit which include the
following : touch-up paintings repair or replacement of corroded piping and flowlines.
Frequency : This maintenance shall be carried out when determine required from the
inspection findings. Normally in between but not exceeding 2 1/2 years from Major
Maintenance and required. Wherever possible, the survey shall coincide/integrate with the
Structural Intermediate Maintenance (refer item no. 1.6.1.2).
Technical Services
1.7.3 Major maintenance
Scope : This maintenance shall be carried out, as identified from the workscoping survey,
and following analysis/review by the responsible party. The scope may include the
following: repair and replacement of pipes, pipe supports and piping components, which
cannot be salvaged by blasting and painting. rectification of misalignments and vibration.
major blasting and painting of corroded areas. Frequency: This maintenance shall be
carried out every five years, but the intervals may change if justified due to actual condition.
It shall always be integrated with the Structural Major Maintenance (refer to item no.
5.1.6.1.3).
Technical Services
1.8 Documentation
All valuable data collected from inspection, testing and maintenance activities shall be
documented in the forms of inspection reports, maintenance close-out reports or a
computerised database system such as IDAMS. The data may be used to facilitate
analysis and trending. The documentation shall be continuously updated and subjected to
annual review.
Technical Services
Page 5
Pressure Vessels And Steam Boilers Rev. 1 December 2000
Section 6
PRESSURE VESSELS AND STEAM BOILERS
Contents
Paragraph Page
1 EXTENT OF COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 VESSELS AND BOILERS CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5.1 Post Installation Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 General Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.4 Internal Corrosion/Erosion Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.5 Periodic Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5.1 Registered pressure vessels and boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5.1.1 Intermediate (interim) survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5.1.2 Major (certification) survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5.2 Non-registered pressure vessels and boilers . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.5.2.1 Intermediate (interim) survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.5.2.2 Major survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 ASSESSMENT AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Page 1
Responsible
Parties
This section covers the guidelines for the inspection and

maintenance of pressure ves sels and steam boilers, including:
Storage drums
Blow down tanks
Separators
Contractor towers
Compressors' suction and discharge pulsation bottles
Pulsation dampers
Knockout pots
Columns
Heat exchangers (air coolers and shell & tube types)
Gas cylinders
Receivers
It also defines the nominal inspection intervals and outlines the

scope for monitoring the conditions in comparison with the design
premises, as well as embodying the application of condition-based
maintenance.
The surveys serve to monitor the deterioration of the pressure

vessels, boilers and accessories that can lead to the degradation of
their integrity; they shall also provide input to the asset holders,
whereby decisions on maintenance or other remedial actions can
be made to ensure the appropriate safety, environment
compliance, reliability and technical integrity of the equipment.
Deviation from this guideline shall be documented in detail and

shall require Carriage management endorsement and PETRONAS
concurrence.
Page 2
Responsible
Parties
The following shall serve as reference and guidelines for this

particular section:
Factories & Machinery Act 1967 (Revised 1974) Factories &

Machinery (Steam Boilers and Unfired Pressure Vessels)
Regulations 1970).
Factories & Machinery (Notification, Certificate of Fitness &

Inspection) Regulations 1970.
OSHA (Occupational Safety and Health Act 1994).
IP Code Part 12 "Pressure Vessel Inspection Safety Code".
API RP 510 "Inspection, Rating and Repair of Pressure Vessel

in Petroleum Refinery Service".
API RP 572 "Inspection of Pressure Vessels".
API RP 573 "Inspection of Fired Boilers and Heaters".
BS5500 "Unfired Fusion Welded Pressure Vessels".
BS5430 Part 1 & 2 "Periodic Inspection, Testing and

Maintenance of Transportable Gas Containers".
ASME Section VIII Div. I "Unfired Boiler and Pressure Vessel

Code".
Page 3
Responsible
Parties
3 VESSELS AND BOILERS CLASSIFICATION
There will be two categories of Pressure Vessels and Steam

Boilers:
Registered (with DOSH)
All pressure vessels and boilers onshore and within 12 nautical

miles from shore. The inspection, certification and registered
with/by the Factories Inspectorate (or their appointed /
approved Certifying Authority).
Non-registered (with DOSH)
All pressure vessels and boilers offshore, beyond 12 nautical

miles from shore. No certification nor registration with FMD is
required. The inspection and technical integrity check of these
equipment shall be carried out by competent personnel
appointed by PCSB.
Scope : Technical
Services
The Inspection and Maintenance Plan must cover both:
Asset Planner
Short term (annual) and
Long term 15 year period or up to the end of the facilities

design life, whichever is shorter).
This rolling plan shall be scheduled for all pressure vessels and
steam boilers. It shall suit the design basis and operating life,
taking into consideration all previous relevant inspection data.
The plan shall be updated on an annual basis.
Page 4
Responsible
Parties
5.1 Post Installation Survey
Scope : Technical
Services
The scope of this survey shall cover a thorough examination to
provide a positive indication and ensure that the equipment has
been constructed as per specified code, and to confirm that there is
no transport or other mechanical damage.
This includes a full external and internal inspection, including a

visual NDT and pressure test, where applicable.
This inspection shall establish a record of the actual condition of

the equipment as a baseline for comparison for subsequent
inspections.
Frequency:
This survey shall be conducted before the vessel or boiler is put

into service the first time.
5.2 General Survey

Assets
Scope :
This survey covers regular visual external observations on the

physical condition of the equipment. No special checklists or
inspection techniques are required.
Frequency :
This survey shall be conducted in conjunction with daily routine

Page 5
Responsible
Parties
5.3 Special Survey
Scope :
Technical
The above survey may be carried out to monitor the integrity of Services
suspected areas in detail (including external/internal visual, NDT,
and pressure tests as necessary). The pressure testing shall be in Assets
accordance with the provisions of the relevant design codes, ie.
API 510 and FMD/DOSH regulations.
Frequency :
The survey shall be conducted following reported leakage /

incidents, dropped objects and/or after completion of any repair or
significant modification works which affect the integrity of the
vessel/boiler.
For steam boilers, the pressure testing shall be carried out at

intervals not less than seven years of service.
5.4 Internal Corrosion/Erosion Monitoring
Scope : Technical
Services
As part of the internal corrosion/erosion monitoring programme, the
UT wall thickness measurements at fixed key points shall be
conducted, ie. during the Intermediate (Interim) Survey.
Frequency :
The Monitoring shall be carried in intervals of six months.
Page 6
Responsible
Parties
5.5 Periodic Survey
5.5.1 Registered pressure vessels and boilers
5.5.1.1 Intermediate (interim) survey
Scope : Technical
Services
The above survey shall be carried while the pressure vessels are in
service or not available for personnel entry. The scope shall cover
the
Visual examination of the entire external including the safety
Relief devices,
Electrical earth bonding, foundation, fittings, etc.
The UT wall thickness measurements at fixed reference points

(as part of the internal corrosion monitoring programme) and
Other NDTs, if applicable may be carried out.
Frequency :
This inspection shall be carried out in intervals of not more than

18 months.
5.5.1.2 Major (certification) survey
Scope: Technical
Services
Thorough visual inspections shall be carried out when the pressure
vessels concerned are released from operations for both internal
and external examinations. The survey shall also include corrosion
condition assessment, NDTs, and B-Scan, if appropriate.
Vessels which cannot be internally inspected (e.g. air/glass

cylinders) shall be pressure tested or B-Scan to verify their
integrity.
If tube corrosion is suspected in the tubes of heat exchangers,

boroscope inspection, eddy current or ultrasonic techniques shall
be used, when considered beneficial.
Page 7
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For steam boilers, the inspection scope shall include visual
inspections covering the insides of: :
boiler shells, drum tubes, furnaces and gas passages
piping, pipe joints and refractory lining
boilers, ie. manhole, drum connections and internal parts,

water / super heater headers
the insides of furnaces and firesides, ie. refractory linings in

furnace, tubes, baffles and dampers.
Frequency :
This inspection shall be conducted, based on previous inspection

results/history but not to exceed as follows:
Air/Gas cylinders/receivers - 24 monthly
Other Vessels - 36 monthly
Steam Boilers - 15 monthly
5.5.2 Non-registered pressure vessels and boilers

5.5.2.1 Intermediate (interim) survey
The above inspection shall be carried out while the pressure Technical
vessels are in service or not available for personnel entry. The Services
scope shall cover a visual examination of the entire external areas
including:
safety relief devices, electrical earth bonding, foundation,

fittings, etc.
UT wall thickness measurements at fixed reference points (as

part of the internal corrosion monitoring programme) and
NDTs, if applicable, shall be carried out.
Frequency :
This inspection shall be conducted every 30 months.
Page 8
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Technical
Thorough visual inspections shall be carried out when the pressure Services
vessels concerned are released from operations for both
internal/external examinations. The Major Survey shall also include
corrosion condition assessment, NDTs, and B-Scan,
if appropriate.
Vessels which cannot be adequately internally inspected (eg.

air/glass cylinders) shall be pressure tested or B-Scan to verify their
integrity.
If tube corrosion is suspected in the tubes of heat exchangers,

boroscope inspection, remote field eddy current in conjunction with
IRIS (Internal Rotary Inspection System), or ultrasonic techniques
shall be used, when considered beneficial.
Frequency :
This inspection shall be conducted, based on previous inspection

results/history but not to exceed as follows:
Air/Gas cylinders/receivers - every 24 months
Other Vessels - every 60 months.
The results of the internal corrosion monitoring shall be timely Technical

analysed and verified against the findings from the Periodic and Services
Special surveys. Sequential data shall be made available and to be
trended and monitored for future plans.
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7 MAINTENANCE
Generally the maintenance includes cleaning and/or blasting of Technical

minor surface corrosion followed by touch-up painting on the Services
external shell and supports, renewal of corroded fittings, welding
repair at corroded internal area and recoating. Assets
The maintenance shall be condition-based, depending on the

inspection findings.
8 DOCUMENTATION
All valuable data collected from the inspection, testing and Technical
maintenance activities shall be documented in the forms of Services
inspection reports, maintenance close-out reports or a
computerised database system such as IDAMS. These may be
used to facilitate analysis and trending.
Inspection and certification status of the pressure vessels shall be

monitored and made available on the Maintenance Control System.
It shall be updated on a monthly basis as a minimum.
Page 10
Rotating Equipment Rev. 1 December 2000
Section 7
ROTATING EQUIPMENT
Contents
Paragraph Page
3 MAINTENANCE STRATEGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Reliability - Centred Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Planned Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Condition-Based Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Proactive / Reliability - Based Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Breakdown Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 CRITICALITY OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 COMPUTERISED MAINTENANCE CONTROL SYSTEM . . . . . . . . . . . . . . . . . 7

7.1 Base - Line Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2 Criticality I Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2.2 Condition - based maintenance plan (CBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2.3 Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2.4 Continuous monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2.5 Lube oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2.6 Turbo - machinery monitoring requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2.7 Reciprocating gas compressors and engine monitoring
requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2.8 Performance testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.2.9 Major inspection and overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.3 Criticality II Equipment (Essential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3.2 Condition based maintenance plan (CBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3.3 Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3.4 Continuous Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3.5 Lube oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Page 1
7.3.6 Major inspection and overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7.3.7 Firewater pumps functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.3.8 Firewater pumps capacity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.4 Criticality III Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.4.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.4.2 Condition Based Maintenance Plan (CBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.4.3 Breakdown maintenance (BM) equipment listing . . . . . . . . . . . . . . . . . . . . . 16

8.1 Assessment And Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2 PPM / CBM Programme Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.1 Maintenance Log Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2 Machinery Key Performance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Page 2
Responsible
Parties
This section summarises the Inspection and Maintenance guidelines

for the Rotating Machinery, which are those vital for the protection, oil
and gas process containment and control of production facilities.
Machinery covered in this definition include :
All turbo machinery power generation and mechanical drive sets
Crude oil transfer and water injection pumps
Centrifugal and reciprocating gas compressors
turbines and reciprocating engines
Utility pumps
This section also defines the approach taken for inspecting and
maintaining the rotating machinery. The inspections serve to monitor
the condition and determine rate of deterioration, which can lead to
degradation of the machinery technical integrity. Maintenance
activities shall then be planned based on the inspection findings,
scheduled and executed in the safest and most cost-effective
manner. The maintenance serve to restore machinery technical
integrity to ensure a safe and reliable operations.
Any deviation from requirements stipulated in this section shall be

properly documented and require Carigali management endorsement
and PETRONAS concurrence.

particular section:
Carigali Guidelines for Inspection & Maintenance of Rotating

Equipment.
Vendor provided Operation and Maintenance Manuals for Major

Rotating Equipment.
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3 MAINTENANCE STRATEGY
To maintain the integrity of the rotating machinery, six types of

maintenance shall be adopted and carried out:
Reliability Centred Maintenance (See 3.1).
Planned Preventive Maintenance (See 3.2).
Condition Based Maintenance (See 3.3).
Proactive Maintenance / Reliability Based Maintenance (See

3.4).
Breakdown Maintenance (See 3.5).
Corrective Maintenance (See 3.6).
3.1 Reliability - Centred Maintenance
Scope: Technical
Services
Reliability-Centred Maintenance (RCM) is a structured procedure to Assets
optimise expenditures by evaluating maintenance strategies based on
operational functions of a process or equipment, and its failure modes
and consequences. The output shall identify the appropriate
maintenance strategies to be applied to the particular equipment.
RCM shall only be considered where it is feasible.
Frequency:
RCM application (if any) shall be determined at the earliest stage of

design, and implemented as soon as operations commence.
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3.2 Planned Preventive Maintenance
Scope: Technical
Services
Planned Preventive Maintenance & Inspection (PPM) is a
time-interval based activity which provides control of the planned Assets
maintenance and inspection, rather than allow the machinery to
breakdown completely. PPM shall be performed based on OEM
recommendations and improved practices, obtained through
operational and maintenance experience.
Frequency:
PPM shall be conducted as per the computerised MCS programme.
3.3 Condition-Based Maintenance
Scope: Technical
Services
The Condition-based Maintenance (CBM) is to measure the relevant
condition of the machinery while in operation, to determine health Assets
status of the machinery. This is done so that failures can be identified
and maintenance requirements can be predicted in advance. The
CBM programme must be in place and to performed accordingly.
Frequency:
The CBM shall be conducted as per the computerised MCS plan.
3.4 Proactive / Reliability - Based Maintenance
Scope: Technical
Services
Proactive or Reliability-Based Maintenance (RBM) will apply
investigative and correct technology towards solving the root cause of Assets
any machinery problem.
Frequency:
RBM shall be applied for any major process failure and / or

mechanical breakdown. The approach shall be applicable in
upgrading and designing out any recurring problems, so as to
improve machinery reliability.
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3.5 Breakdown Maintenance
Scope: Technical
Services
Breakdown Maintenance (BM) shall be carried out to fix or maintain
the equipment only when it breaks down. This is only applicable for Assets
Criticality III (See 5.5.7.4) equipment and only when proven cost
effective.
Frequency
BM shall be carried out as soon as it is reasonably practical, as

required.
3.6 Corrective Maintenance
Scope: Technical
Services
The Corrective Maintenance (CM) is usually a follow-up corrective
actions to all other types of maintenance. It is to rectify any anomaly Assets
found during the execution of the PPM / CBM programme and also
after breakdown occurs.
Frequency:
The CM shall be conducted as when found required.
4 CRITICALITY OF EQUIPMENT
Scope : DDE
The classification of equipment criticality shall be made and reviewed, Technical

and this may be used in determining the degree of condition Services
monitoring. The equipment critically shall be classified as follows;
Assets
Criticality 1 - Vital (See 7.2)
Criticality 2 - Significant (See 7.3)
Criticality 3 - Nonessential (See 7.4)
Frequency :
The classification shall be done during the design stage, based on

available FDP data, and to be reviewed/updated if the relevant criteria
changes.
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Scope : Technical
Services
The Inspection and Maintenance programme (which include the
Planned Preventive Maintenance & Inspection (PPM) and Assets
Condition-Based Maintenance (CBM)) for all major rotating equipment
shall be planned/scheduled accordingly.
Frequency:
This Plan shall be reviewed / updated regularly.
6 COMPUTERISED MAINTENANCE CONTROL SYSTEM
Scope : Technical
Services
A proper computerised maintenance control system (MCS), shall be
maintained, to plan and schedule all CBM and PPM routines. The Assets
system shall be able to auto generate inspection and maintenance
work orders, as and when necessary.
Frequency:
The system shall be updated in annual basis.
Page 7
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7.1 Base - Line Inspection
Scope : Technical
Services
Base-line Surveys shall be carried out; this shall include:
Assets
Through visual inspection
Logging of operating parameters
Performance testing
Vibration measurement
Control and safety system inspection and testing
Collection of CBM baseline measurements, etc.
The interface with other systems shall also be checked. The

gathered data will serve as a reference and provide a comparison
basis for future inspections.
Frequency:
This Inspection shall be carried out during and after commissioning,

and after overhaul of the equipment.
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7.2 Criticality I Equipment
7.2.1 Definition
The machinery is categorised as vital in the following scenarios:
When breakdown occurs and an immediate interruption in

production operations occurs.
Repair costs for overhauling the machinery is significant .
Examples
All turbo-machinery power generation and mechanical drive

sets
Continuous duty (greater than 150 HP) reciprocating engines

and compress
MOL/COT Pumps where NO back-up exists or high order of

maintenance problem exists.
7.2.2 Condition - based maintenance plan (CBM)
Scope : Technical
Services
The CBM is to measure and monitor the condition of the machinery,
while in operation, to determine the health status. This is done in Assets
order to identify failures and predict maintenance requirements in
advance.
For Criticality I equipment, the CBM programme shall be in place and

performed accordingly.
Frequency :
This Plan shall be detailed out in the Computerised MCS, and

analysed / updated on annual basis.
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7.2.3 Daily inspection
Scope : Technical
Services
Routine and visual inspection for physical damage or leaks from
associated pipeworks and seals shall be carried out. Key operating Assets
parameters shall be recorded, reviewed and downloaded into a
computerised system by the operators. All significant operating
parameters shall be trended to automatically detect faults / predict
failures and the corrective action work order shall be automatically
generated.
Frequency :
As initial frequently, this Inspection shall be carried out twice daily, but
more often if possible.
7.2.4 Continuous monitoring
Scope :
Technical
Continuous Monitoring shall be conducted on the operating conditions Services
to detect potential defect/malfunction in advance; this is done so that
appropriate preventive maintenance can be effected. Assets
For ALL turbo machinery, the vibration and temperature on-line

monitoring systems shall be installed for continuous monitoring and
auto shutdown of the machine.
Frequency :
The Monitoring shall be continuous, and is part of CBM programme.
7.2.5 Lube oil analysis
Scope : Technical
Services
Lube Oil Analysis shall be conducted to check for oil conditions. The
Infrared and Metal Analysis shall be performed when determined to Assets
be beneficial.
Frequency :
The analysis shall be performed on a monthly basis, as part of CBM

programme.
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7.2.6 Turbo - machinery monitoring requirements
Scope : Technical
Services
In addition to Continuous Monitoring (5.5.6.2.4), the minimum
monitoring requirements for the Turbo-Machinery system shall be as Assets
follows:
Vibration at all key points
Thrust bearing position
Thrust bearing and lube oil drain temperatures
Lube oil consumption
Frequency :
The monitoring shall be performed as per the CBM programme.
7.2.7 Reciprocating gas compressors and engine monitoring

requirements
Technical
Scope :
Services
The Monitoring system for the above shall include the following:
Assets
Vibration
Exhaust pyrometers for each cylinder
PT/PV diagnosis
Frequency :
The monitoring shall be performed as per the CBM programme.
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7.2.8 Performance testing
Scope : Technical
Services
Integrity checks on reciprocating compressors and the operational
performance test for all other major rotating machinery shall be Assets
conducted as determined by operational requirements and known
operational and maintenance experience.
Frequency :
As a guide, the initial frequency of the testing shall be every 12

months.
7.2.9 Major inspection and overhaul
Scope : Technical
Services
Major overhauls and invasive inspections shall be performed utilising
the best combination of OEM recommendations, CBM techniques, Assets
and established operation and maintenance practices.
Frequency:
The timing shall be based on the best combination of OEM

recommendations, CBM techniques, and established operation and
maintenance experience.
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7.3 Criticality II Equipment (Essential)
7.3.1 Definition
The Machinery is categorised as essential if when breakdown occurs, Technical

there is NO: Services
Immediate loss of production operations, or Assets
Compromise of safety, due to the availability of the backup unit,

or other mitigating factors.
Examples:
Firewater pumps with installed back-up units
Emergency Generator Sets
Air compressors
MOL/COT Pumps with installed back-up unit.
Sea Water Lift pumps.
7.3.2 Condition based maintenance plan (CBM)
Scope : Assets
The CBM is to measure and monitor the condition of the machinery

while in operation, to determine the health status. This is done to
identify potential failures and predict maintenance requirements in
advance.
For Criticality II equipment, the CBM programme must be in place

and performed accordingly.
Frequency :
The CBM shall be as per the MCCS and carried out at a minimum on
a monthly basis.
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Parties
7.3.3 Daily inspection
Scope : Assets
Routine and visual inspection to check for physical damage or leaks

from associated pipe works and seals shall be carried out. Operating
parameters shall be recorded, reviewed and downloaded into a
computerised system by the operators. All significant operating
parameters shall be trended to automatically detect faults / predict
failures and the corrective action work order shall be automatically
generated.
Frequency :
As initial frequency, this inspection shall be carried out twice daily, but
more often if possible.
7.3.4 Continuous Monitoring
Scope : Technical
Services
Continuous Monitoring shall be conducted on the operating conditions
to detect potential defect/malfunction in advance; this is done so that Assets
appropriate preventive maintenance can be effected.
However, the installation of continuous vibration monitoring

instrumentation is OPTIONAL for Criticality II machinery and is based
mainly on individual equipment needs and cost effectiveness.
Frequency :
The monitoring shall be continuous, and is part of the CBM

programme.
7.3.5 Lube oil analysis
Scope : Technical
Services
Lube oil shall be analysed to check for oil conditions. The Infrared
and Metal Analysis shall be performed when determined to be Assets
beneficial.
Frequency :
The analysis shall be performed as required and is part of the CBM

programme.
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Parties
7.3.6 Major inspection and overhaul
Scope : Technical
Major Inspections and Overhauls (for Stand - By Reciprocating Services
machinery only) shall be performed utilising the best combinations of
CBM techniques, OEM recommendations established operational and Assets
maintenance practices.
Frequency :
The timing shall be based on the best combination of OEM
recommendations, CBM techniques, and established operational and
maintenance experience.
7.3.7 Firewater pumps functional test
Scope : Technical
The above test shall be carried out on all firewater pumps. Services
Frequency : Assets
The test shall be carried out weekly basis.
7.3.8 Firewater pumps capacity test
Scope : Technical
The Capacity test shall be carried out on all firewater pumps. Services
Frequency : Assets
The test shall be carried out on a monthly basis.
7.4 Criticality III Equipment

7.4.1 Definition
Machinery is categorised as nonessential when:
breakdown occurs, there is NO significant impact on production

and/or safety.
Examples:
HVAC (High Voltage Air Conditioning) System
General Utility pumps
Page 15
Responsible
Parties
7.4.2 Condition Based Maintenance Plan (CBM)
The CBM shall measure the condition of the machinery while in

operation, to determine health status. This is done so that failure can Technical
be identified and maintenance requirements can be predicted in Services
advance.
Assets
For Criticality III equipment, the CBM can be applicable only when
determined to be beneficial.
Frequency :
The programme (if any) shall be detailed out in the computerised

MCS, and analysed/updated on annual basis.
7.4.3 Breakdown maintenance (BM) equipment listing
Breakdown Maintenance (BM) is to fix or maintain the equipment Technical

only when it breaks down. It shall be employed ONLY when it is Services
proven to be cost effective.
Asset
All machinery that falls under this BM listing shall be clearly identified
and listed in the computerised maintenance database system.
Frequency :
The listing shall be subjected to annual review and update.

8.1 Assessment And Corrective Action
Any anomaly identified / found during the execution of PPM/CBM

programmed shall be automatically captured (in MCS) and analysed Technical
for appropriate remedial actions. Subsequent maintenance work Services
orders shall then be generated.
Assets
Any repetitive problems identified shall however be analysed in more
detail, and decision on the application of Reliability Based
Maintenance approach shall be made. The above shall be carried out
as soon as it is reasonably practical.
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8.2 PPM / CBM Programme Analysis
Scope: Technical
Services
The results of both the PPM and CBM programmes shall be reviewed
and revised accordingly, to provide the best balance of these two DDE
types of maintenance for continuous improvement.
Assets
Frequency :
The analysis shall be done prior to updating the PPM / CBM

programme. As a guideline, the review shall be performed on annual
basis.
9 DOCUMENTATION
9.1 Maintenance Log Book
The Maintenance Log Book shall be kept and updated accordingly, to Assets
record all Inspection and Maintenance activities (however minor) of
the machinery. It shall as a minimum include:
Starts and shutdowns of the machinery
Lube oil consumption record, etc.
Summary of all maintenance activities performed
The recording shall be carried out as when required/applicable.
Page 17
Responsible
Parties
9.2 Machinery Key Performance Report
Assets
The "Machinery Key Performance Indices" report shall cover the
Criticality I (vital) major equipment usage and availability data. It shall
be submitted to PETRONAS, and as a minimum include:
% Availability
Run hours per start
% Usage
% Equipment out of service
Mean Time Between Failure
Mean Time Between Repairs
Maintenance cost per horse power
The report shall be submitted on a monthly basis.
Page 18
Storage Tanks Rev. 1 December 2000
Section 8
STORAGE TANKS
Contents
Paragraph Page

4.1 Acceptance And Handover Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Pre-Service Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Routine Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4 Annual External Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Full Internal and External (Workscoping) Survey . . . . . . . . . . . . . . . . . . . . . . 5
4.6 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.7 Internal Corrosion Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 Routine / Minor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 Major Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Page 1
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Parties
This document summarises the guidelines for the inspection and

maintenance of atmospheric and low pressure storage tanks used
to store crude oil, intermediate and refined product, gas,
chemicals and water. The inspection and maintenance of high
pressure tanks designed to operate at pressures of more than 56
mbar are more closely related to that for pressure vessels.
The inspection activities generally determine the physical condition

of the tank, the rate of deterioration and, if possible, the causes of
deterioration. With these factors known, proper measures can be
taken to ensure adequate safety, reliability and economic
operation by applying appropriate maintenance.
Deviation from guidelines stipulated under this section shall be

documented in detail and shall require Carigali management
endorsement and PETRONAS concurrence.
Page 2
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Parties
The following shall serve as references and guidelines for this

particular section:
API Guide for Inspection of Refinery Equipment Chapter XIII

- "Atmospheric and Low-Pressure Storage Tanks"
API 653 "Tank Inspection, Repair, Alteration and

Reconstruction"
BS 2654 "Specification for Vertical Steel Welded Storage

Tanks with Butt-Welded Shell for Petroleum Industry"
EEMUA 159 "Recommended for In-service Inspection of

Aboveground Vertical Cylinder Steel Storage Tanks",
Engineering Equipment and Materials Users Association,
London, 1993.
An Inspection and Maintenance plan which suits design basis and Technical
operating life shall be available. This plan shall c over: Services
Short term. Annual look ahead in detail, and Assets
Long term. Covering a period of 15 years or up to the end of

structure design / economic life, whichever comes first.
It shall also take into consideration all previous relevant inspection

data and analysis. The plan shall be updated on annual basis.
Page 3
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Parties
4.1 Acceptance And Handover Survey
Scope: Technical
Services
As a minimum this survey shall include a thorough examination of
the storage tanks, to ensure that the storage tank has been Assets
constructed in accordance with the design specification and to
confirm that there is no mechanical damage.
Frequency:
The survey shall be carried out after installation or prior to

handover to Assets.
4.2 Pre-Service Inspection
Scope: Technical
Services
As a minimum this inspection shall include a thorough internal and
external visual inspection and testing which includes all mounting, Assets
piping, components, electrical earth bonding and lighting
protection, floating roof, fire fighting system, etc.
Frequency:
The survey shall be carried out before the tank is put into service
for the first time.
4.3 Routine Survey
Scope: Assets
The above survey basically involve regular visual observation on

the physical condition of the tank, bundwall and foundation
condition, to check for any leakage. Any findings of anomalies
shall be reported immediately for remedial actions. No specific
check lists or inspection techniques will be required.
Frequency:
The survey shall be carried out in conjunction with daily routine

Page 4
Responsible
Parties
4.4 Annual External Inspection
Scope: Technical
Storage tanks shall be externally inspected on foundation, bottom, Services
shell, stairs, and roof, cathodic protection system (if any), venting
and safety relief system, bundwalls, dykes, electrical earth
bonding and lightning protection, protective coating, etc.
On the fifth year inspection the scope shall be extended to include

UT thickness gauging of the shell and roof plates. As a minimum 5
readings shall be taken on each plate.
Frequency:
The survey shall be carried out annually.
4.5 Full Internal and External (Workscoping) Survey
Scope: Technical
The scope of the above activities shall as a minimum shall include: Services
Internal cleaning in accordance with API RP 2015
Visual inspection and corrosion survey on bottom, shell, roof

and pipeworks,
Coating survey
UT thickness measurement on the two most bottom course

where corrosion is likely to occur due to water .
Other NDTs as necessary.
Dimensional survey
The workscoping survey is to identify all necessary works to be

included under the next Major Maintenance program to bring the
tank to API 653 standard.
Frequency:
The inspection and survey shall be carried out together after
seven years in operation and subsequently at intervals not
exceeding 10 years.
They shall be carried out timely, within one year prior to Major
Maintenance of the tank.
Page 5
Responsible
Parties
4.6 Special Survey
Scope: Technical
Services
The survey may include a thorough visual examination and NDT if
required of the suspected areas in detail. This is to confirm that
there is no physical damage that affect the integrity of the storage
tank.
Frequency:
The survey shall be conducted based on the findings of previous

surveys and / or after major disaster such as earthquake, flood
and any reported incident, as and when considered appropriate by
the responsible party.
4.7 Internal Corrosion Monitoring
Scope: Technical
Services
Wet tanks, where areas are in contact with water shall be
monitored for internal corrosion. One or more of the following
method can be utilised:
CP level monitoring where sacrificial anodes have been

installed,
UT wall thickness key point monitoring within 1.5m shell plates

from the foundation level,
Weight loss coupons for process corrosion monitoring
ER probes monitoring in drain lines via access fittings
Iron counts in drain lines to check the corrosivity of the water

contained in the tank.
Frequency:
Cathodic Protection Survey 6 monthly

Weight loss & ER Probes 6 monthly
Iron counts 6 monthly
Wall thickness loss 6 monthly
Page 6
Responsible
Parties
Technical
There shall be a timely review and assessment of data. Trends Services
from sequential data shall be monitored for future plans.
Remedial actions shall be based on criticality of anomaly and

found defects.
Suitable databases such as IDAMS shall be used to manage the

data.
6 MAINTENANCE
6.1 Routine / Minor Maintenance Assets
Scope:
The scope shall include one or more of the following :
Grass cutting,
Touch-up painting of external shell,
Structural minor repairs, etc., as identified during daily

operations and / or following analysis of inspection results.
Frequency:
It is to be condition based, as when necessary.
Page 7
Responsible
Parties
6.2 Major Maintenance
Scope: Technical
Services
The scope of the above shall be based on the Workscoping Assets
Survey findings and may include the following :
Repair / replacement of corrosion protection coatings.
Repair and replacement of the bottom plates (partially or full) if

required.
Cleaning / blasting of minor surface corrosion followed by

touch-up painting on tank bottom plates, tank shell, roof
structures, internal pipeworks and fittings, etc.
Tank jack-up / repair due to uneven or excessive tank

settlement including toe deformation (annular / shell plates) or
eroded tank pad, etc.
Frequency:
The maintenance schedule is based on normal intervals of 10

years but may changed if justified due to condition as found.
7 DOCUMENTATION
Technical
All results and findings data from the Inspections and Maintenance Services
program and activities for storage tanks shall be kept in suitable
database system such as IDAMS for easy storage, retrieval, Assets
analysis and trending.
The documentation shall be continuously updated and subjected

to annual review.
Page 8
Cranes And Lifting Equipment Rev. 1 December 2000
Section 9
CRANES AND LIFTING EQUIPMENT
Contents
Paragraph Page
2 REFERENCE AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 CLASSIFICATION OF CRANES AND LIFTING

EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5.1 Post Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.2 Functional Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.3 Proof Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.4 Cargo Handling Equipment (CHE) Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.5 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.2 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Page 1
Responsible
Parties

maintenance of cranes and other lifting equipment. The cranes
shall include jib crane, pedestal crane, gantry crane, overhead
traction crane, etc.; whilst the lifting equipment includes davit,
monorail, chain hoist, deck & tackle, lifting boom, etc..
These inspections and maintenance will establish a continuing

level of confidence in the fitness for purpose of the crane, and
lifting equipment and provide data which enables the timely
performance of maintenance or other remedial actions, vital to the
safety and reliability of the crane and lifting equipment and their
associate fittings.
Deviation from specifications stipulated under this section shall be

endorsement and PETRONAS concurrence .
2 REFERENCE AND GUIDELINES

particular section:
PGIM "PETRONAS Guidelines for Inspection and

Maintenance of Production Facilities"
CARIGALI Operation Philosophy
API 2C "Specification For Offshore Cranes"
API RP 2D "Recommended Practice for Operation and

Maintenance of Offshore Cranes"
BS 5744 "Statutory Periodic Testing and Examination of

Cranes"
Acts and Regulations for Onshore cranes other than those

operated manually:
(i) Factory and Machinery Act 1967 (Revised 1974)
(ii) Factory and Machinery (Notification, Cert. of Fitness

and Inspection) Regulations 1970.
Page 2
Responsible
Parties
An Inspection and Maintenance program for all cranes and lifting Technical
equipment shall be made available. Services
Suitable database system for automatic generation of inspection Assets

or maintenance work orders is to be in place. A Competent
Person (C.P) should be assigned to coordinate the cranes and
lifting equipment inspection and maintenance activities.
The plan shall also take into consideration all previous relevant
inspection data and analysis. The updating of the plan shall be on
annual basis.
4 CLASSIFICATION OF CRANES AND LIFTING

EQUIPMENT
There will two categories of cranes and lifting equipment:
Registered with (DOSH)
All cranes and lifting equipment onshore and within 12

nautical miles from shore. All inspection, registration and
certifications are to be performed by DOSH Factories
Inspectorate (in absence, their appointed/approved Certifying
Authority)
Non-Registered (with DOSH)
All cranes and lifting equipment installed beyong 12 nautical

miles from shore. An independent certifying authority can be
engaged for inspection. No certification nor registration with
DOSH is required.
Page 3
Responsible
Parties

5.1 Post Installation Inspection
Scope:
As a minimum, the scope shall cover:
Through visual examination, and
Proof Load Test
NDT, if necessary
For Registered cranes and lifting equipment, the inspection,

registration and certification are to be performed by Factories
Inspectorate (or their appointed/approved certifying authority).
For Non-Registered cranes and lifting equipment, an independent

certifying authority can be engaged for inspection.
All relevant documentation, mill and test certificates, design

calculations and drawings shall be reviewed.
Frequency:
This inspection shall be conducted prior to hand over to the
cranes to Carigali and departure of Installation Contractor from
site.
5.2 Functional Load Test
Scope: Technical
Load test with a load equal to SWL to demonstrate satisfactory Services
operation, efficiency of overload and weight load indicator, limit
switches, etc. The test shall be witnessed and approved by an Assets
independent certifying authority.
Functional load test can be eliminated when Proof Load Test is

conducted on that particular year. All relevant documentation, mill
and test certificates, calibration certificates shall be reviewed
before the cranes are put into service for the first time.
Frequency:
The test shall be conducted annually.
Page 4
Responsible
Parties
5.3 Proof Load Test
Scope: Technical
Services
A Proof Load Test shall be conducted in accordance with the
manufacturer's recommendation or the load test procedure Assets
recommended by API RP 2D. It is to confirm that the crane has
appropriate safety factor for designated Safe Working Load
(SWL).
The testing shall be witnessed and approved by Independent

Certifying Authority.
Frequency:
The test shall be performed prior the cranes are being placed into
service for first time and subsequently not exceeding five year
intervals and also after any major repairs.
5.4 Cargo Handling Equipment (CHE) Survey
Scope: Technical
Services
The scope as a minimum shall include thorough visual inspection
on all slings, belts, shackles, wire ropes, cargo net, swivels and Assets
shieves, etc.
The Safe Working Load (SWL) of all slings shall be clearly

marked and the colour coding will be in accordance with the latest
PCSB HSE procedures.
All expired CHE shall be recertified by Third Part Surveyor (for

reuse) or disposed properly.
Frequency:
The survey shall be carried out before the items are put into
service and subsequently at 6 month intervals.
Page 5
Responsible
Parties
5.5 Special Survey
Scope: Technical
The scope may include a through visual inspection and NDT, if Services
required, of the crane to confirm that there is no physical damage.
Frequency:
The survey shall be done after any reported incidents and as
when considered appropriate by the responsible party.

Technical
There shall be a timely review and assessment of data. Remedial Services
actions shall be based on criticality of anomaly and found defects.
Trends from sequential data if available, shall be monitored for

future plans. Suitable database such as IDAMS shall be used to
manage the data.
Inspection reports complete with recommendations for remedial

actions where appropriate shall be timely issued to relevant
parties to be considered for implementation.
7 MAINTENANCE
7.1 Preventive Maintenance
Scope: Assets
This includes an adjustment of components such as operating

mechanism and control systems, limit switches, swing circle
assembly, prime mover and hydraulic system, as per
manufacturer's recommendations and in-house computerised
Maintenance Control System programme. Moving parts are also
to be lubricated.
A Competent Person (C.P.) should be assigned to coordinate the

maintenance activities and maintain the database.
Frequency:
As recommended by manufacturer and detailed out in MCS

programme.
Page 6
Responsible
Parties
7.2 Corrective Maintenance
Scope: Technical
Services
The scope includes repairs or replacement of critical components
which are found to be missing, cracked, broken, badly corroded, Assets
bent or excessively worn out and deteriorated. The components
include:
Parts of operating mechanism,
Parts of the crane structure, and
Other Cargo Handling Equipment
For any major repairs or modifications, the cranes shall be

subjected to Functional or Proof Load Test before returned back
into service.
Frequency:
It will be condition based i.e. following analysis of results / findings

of the above inspection and test.
8 DOCUMENTATION
All Inspections and Maintenance program and activities for all Technical
crane and lifting equipment shall be kept in suitable database Services
system such as IDAMS and MCS for easy retrieval and analysis.
The database system shall be able to highlight any outstanding Assets
items and automatically generate Inspection or Maintenance work
orders as appropriate.
A Competent Person (C.P.) should be assigned to manage the

database on the cranes and lifting equipment.
The documentation shall be continuously updated and subjected

to annual review for completeness.
Page 7
Section 10
EXPORT AND SUPPORT FACILITIES
Contents
Paragraph Page
2 REFERENCE AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 CLASSIFICATION OF FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.1 Floating Storage And Offloading (FSO) Vessel . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1.1 Annual class survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1.2 Special class survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2.1 Boiler survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2.2 Ballast tank survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2.3 Special inert gas system survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2.4 Crane survey and load test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1.2.5 Continuous survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1.2.6 Underwater inspection in lieu of dry-docking survey (UWILD) . . . . . . . . . . 9
5.1.3 Annual statutory survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Single Point Mooring (SPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2.1 Single buoy mooring (SBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2.1.1 Installation acceptance survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2.1.2 Periodical survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.1.3 Special survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.2 Single point turret (SPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2.1 Annual reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2.2 Above water survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2.3 Underwater survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2.4 Special periodical survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.2.5 Special survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Cargo Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3.1 Hydrotest of new / used hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3.2 Post service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3.3 Submarine hose inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3.4 Pre-berthing inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Mooring Buoy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4.1 Annual survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Page 1
5.4.2 Special periodical survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.4.3 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 Floating Storage And Offloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Single Buoy Mooring (SBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2.1.1 During installation acceptance survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2.1.2 During periodical survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2.1.3 During special survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.2 Hose change-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.3 Body overhauls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3 Single Point Turret (SPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4 Cargo Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4.1 Change-out and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.5 Mooring Buoy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Page 2
Responsible
Parties
This section specifies the inspection and maintenance guidelines of

export and support facilities. The export facilities include Floating
Storage and Offloading (FSO) Vessel, Floating Production Storage
and Offloading (FPSO) Vessel, Single Point Mooring (SPM) System
(consisting of Single Buoy Mooring and Single Point Turret) and the
associated cargo hoses. The support facility only covers mooring
buoy which is used to temporarily moor small marine vessels whilst
the vessels are not in operation i.e. on standby.
This guideline is intended to provide a foundation to define optimum

level of inspection and maintenance for preserving the long term
fitness-for-purpose of its facilities. Responsible parties are also
identified for each activity.

Page 3
Responsible
Parties
2 REFERENCE AND GUIDELINES
The following shall serve as references and guidelines for this

particular section :
ABS Guide for Building & Classing Floating Production,

Storage and Offloading Systems
ABS Guide for Underwater Inspection in lieu of Dry-docking

Survey
ABS Guide for Certification of Cranes
ABS Rules for Building & Classing Single Point Moorings
OCIMF Single Point Mooring Maintenance and Operation

Guide
OCIMF Guide to Purchasing, Manufacturing and Testing of

Loading and Discharge Hoses for Offshore Moorings
OCIMF Guide for the Handling, Storage, Inspection and

Testing of Hoses in the Field
International Convention for the Safety of Life at Sea (SOLAS)

and its latest amendments
International Convention for the Prevention of Pollution of

Ships.
Page 4
Responsible
Parties
3 CLASSIFICATION OF FACILITIES
The facilities will be two categories of Export and Support Facilities
Classed Facilities
FSO / FPSO and its SPT, all the hull structure, machinery,
associated equipment and installation shall be inspected and
maintained annually and periodically in accordance with Class
requirement to maintain their integrity, safety and seaworthiness.
Basically, there are three types of surveys namely Annual Class
Survey, Special Class Survey and Annual Statutory Survey.
Normally, a Class surveyor attendance is required during each
survey.
Unclassed facilities
SBM, cargo hoses and mooring buoy, periodical inspection and

maintenance plan shall be in place.
An inspection and maintenance plan which suits design philosophy Technical

and operating life shall be available. This plan shall covers: Services
Short term (annually and up to five years look ahead) and
Long term (period of 15 years or up to end of facilities design /

economic life) plan shall be available.
It shall take into consideration of all previous relevant inspection

data and analysis. The plan shall be updated on an annual basis.
Page 5
Responsible
Parties
5.1 Floating Storage And Offloading (FSO) Vessel
5.1.1 Annual class survey
Scope: Technical
Services
The Annual Class Surveys consist of Hull Survey, Machinery
Survey, Inert Gas System (IGS) Survey and Cargo Gear Survey. At
each annual survey, the following shall be generally examined as far
as can be seen and placed in satisfactory condition:
Hull Survey
Structural areas of the hull; decks and accommodation spaces;

protection of hatch and openings; cargo tanks and their handling
and loading system; deck machinery; fire fighting equipment and life
saving appliances; power supply and communication facilities.
Machinery Survey
Auxiliary machinery and electrical installation; bilge pumping system;

testing of communication means between machinery and cargo
control room; access arrangement including emergency escape
route.
Inert Gas Survey (IGS) Survey -
All components and piping; confirmation of proper operation of

blowers and scrubbers, deck seals and non-return valves; verify
operation of all remotely operated / automatically controlled valves,
soot blowers interlocking feature and all alarms and safety devices.
Cargo Gear Survey
All gears related to cargo handling and functional test of crane

including safety protective and limiting devices and boom angle
indicator.
Frequency:
The above survey shall be conducted on an annually basis.
Page 6
Responsible
Parties
5.1.2 Special class survey
5.1.2.1 Boiler survey
Scope: Technical
Services
General examination of boilers, superheaters and economisers
internally and externally, boiler mountings and foundation, proper
operation of safety valves by in-situ pop-testing, testing of
instrumentation & control system and if necessary hydrostatic
pressure test on the boiler / superheaters. Cleaning of tubes, NDT
measurement are to be carried out every alternate boiler survey (5
years)
Frequency:
The above survey shall be conducted every 2 ½ years but not

exceeding 3 years.
5.1.2.2 Ballast tank survey
Scope: Technical
Services
Class rules call the above as Intermediate Survey. Inspection of
tanks or other spaces used for sea water ballast shall be carried out
and if fully protected, to verify the continued effectiveness of such
corrosion control arrangements. Thickness gauging and means of
access to the upper parts of the tanks may be required.
Frequency:
The above survey shall be conducted every 2 ½ years.
5.1.2.3 Special inert gas system survey
Scope: Technical
Services
In addition to the requirement of the Annual IGS Survey, all valves,
pipe and fittings, scrubber, blowers, expansion pieces, seawater
pumps, deck seal units and stand pipe for cargo tank purging shall
be thoroughly examined.
Frequency:
The above survey shall be conducted every five years.
Page 7
Responsible
Parties
5.1.2.4 Crane survey and load test
Scope: Technical
Services
The Class rules call the above survey as Cargo Gear Retesting
Survey. In addition to the requirement of the Annual Cargo Gear
Survey, the crane shall be subjected to Proof Load Test of 25%
above the Safe Working Load using movable known weights and
load cell. The crane shall be capable of lifting and hold the load for
at least five minutes, hoisting and lowering of main and auxiliary
hoist load and boom; slewing and luffing.
The tests shall be repeated at two locations of opposite sides of

slewing circle at minimum, maximum and intermediate radio. The
operation and test also include brakes, safety (fail safe) and limiting
devices; load moment and boom angle indicator.
After being tested, each crane together with all critical components
shall be examined to see whether any part has been damaged or
permanently deformed.
Frequency:
The above test shall be conducted every five years.
5.1.2.5 Continuous survey
Scope: Technical
Services
This survey is opted in lieu of Special Periodical Survey carried out
every five years. In addition to all annual hull and machinery survey
requirements, all means of protection to openings, decks,
hatchways, tanks, watertight bulkheads, loadline marks and
independent cargo tanks shall be examined in position and that they
are placed in good condition and are readily accessible. Only 20%
of the list of items to be surveyed in the Special Periodical Survey to
be conducted annually in regular rotation over five years. This is to
avoid total shutdown of FSO.
Frequency:
The above survey shall be carried out annually in conjunction with

Annual Class Survey.
Page 8
Responsible
Parties
5.1.2.6 Underwater inspection in lieu of dry-docking survey (UWILD)
UWILD - Intermediate Survey
Scope: Technical
Services
Only visual and physical examination of the outside shell plating
above the waterline and side and bottom plating below waterline DDE
shall be carried out including sea chest and all openings to the sea
using ROV or diver.
Frequency:
The survey shall be conducted every 2.5 years in conjunction with

any subsea structural inspection in the vicinity.
UWILD - Special Survey
Scope: Technical
Services
In addition to Intermediate UWILD Survey, the outside and bottom
plating (both above and below waterline) shall be cleaned as DDE
necessary. All openings to the sea, including sanitary and other
overboard discharges together with their valves shall be examined
internally and externally. The vessel underwater areas shall be
sufficiently cleaned to permit meaningful examination and
photography by diver. Overall and spot cleaning may be required at
the discretion of the attending Class surveyor.
The underwater inspection shall be carried out by qualified diver

using Close Circuit Television (CCTV) with two-way communication
capable of being monitored by the Surveyor and photographic
documentation as required.
Frequency:
The survey shall be conducted every 5 years in conjunction with any

subsea structural inspection in the vicinity.
Page 9
Responsible
Parties
5.1.3 Annual statutory survey
Scope: Technical
The following types of survey to be carried out as required by Services
statutory bodies:
Cargo Ship Safety Equipment Survey
Cargo Ship Safety Construction Survey
Loadline Inspection and Certificate Endorsement
International Convention for the Prevention of Pollution from

Ship (MARPOL) Survey.
A 'Statement of Fact' will be issued by Class on behalf of the

regulatory body for compliance of the above except the MARPOL
Survey. For MARPOL Survey, the 'Certificate of Compliance' will be
issued directly by The Marine Department as Malaysia now is a
signatory to the MARPOL convention.
Frequency:
The survey shall be conducted annually in conjunction with the
Annual Class Survey.
5.2 Single Point Mooring (SPM)

5.2.1 Single buoy mooring (SBM)
5.2.1.1 Installation acceptance survey
Scope: Technical
To confirm full performance and compliance with the installation Services
scope of work prior to issuing 'Installation Acceptance Certificate'.
This is to ensure no mechanical / structural damage during transport DCE
and to establish status of SBM and its associated component. Full
internal / external examination, visual inspection, NDT and pressure
testing, where applicable, shall be carried out. This survey shall be
performed by an independent third party prior to acceptance and put
into service for the first time.
Frequency:
The survey shall be conducted during initial installation and prior to
contractor's departure from the site.
Page 10
Responsible
Parties
5.2.1.2 Periodical survey
Technical
Above water Services
Scope: Assets
To monitor condition of all above water components and

appendages of the SBM structure and its associated equipment
such as cargo hose and mooring hawser. In addition, preberthing
checks are also carried out. A thorough survey shall be carried out
which includes visual examination and NDT of selected component.
Frequency:
The survey shall be conducted on a monthly basis for condition

monitoring. For pre-berthing checks, ranges from daily to weekly
depending on tanker schedule. If necessary a more thorough survey
shall be conducted annually.
Below Water
Technical
Scope: Services
To carry out detailed inspection of all subsea components and DDE

appendages of the SBM from the PLEM all the way to the surface to
ensure no deterioration or anomalies.
Frequency:
The survey shall be conducted annually in conjunction with any

subsea structural inspection in the vicinity.
5.2.1.3 Special survey
Scope: Technical
Services
To check the structural integrity such as collision damage, torn off
SBM parts, anodes, bent structure, leaks, etc. DDE
Frequency:
The survey shall be conducted as required, after any collision

incident or severe storm, based on incident / damage reports on the
SBM parts.
Page 11
Responsible
Parties
5.2.2 Single point turret (SPT)
5.2.2.1 Annual reporting
Scope: Technical
Services
Survey reports and checklist has to be submitted and filed with the
Class. They serve as evidence to certify that regular and annual
inspection and maintenance have been against with an agreed
schedule.
Frequency:
The reports shall be submitted annually.
5.2.2.2 Above water survey
Scope: Technical
Services
Survey includes above water, top side structures, deck and mooring
equipment, hatchways, pipes and valves swivel, etc. and operability
of the turret system. Class surveyor attendance is not required
during each above water survey.
Frequency:
The first survey shall be conducted 6 months after installation date

and annually thereafter in conjunction with FSO Annual Class
Survey.
5.2.2.3 Underwater survey
Scope: Technical
Services
Survey includes the underwater structure, mooring chains including
their tension, chain table and lower bearing, corrosion protection DDE
system, risers and their supporting system, starting from the PLEM
all the way to the surface. Class surveyor attendance is required in
this survey.
Frequency:
The survey shall be conducted every 2.5 years in conjunction with

FSO UWILD Survey.
Page 12
Responsible
Parties
5.2.2.4 Special periodical survey
Scope: Technical
Services
In addition to Above and Below Water Survey, this survey shall also
include entire length of mooring chain & components, accessible DDE
structural members and anodes (replace, if necessary), NDT on
critical welds and chain angle measurement. Swivels shall be
stripped for internal inspection and overhauled; seal shall be
replaced if found leak. Class surveyor attendance is required.
Frequency:
The survey shall be conducted every five years in conjunction with

FSO UWILD Survey.
5.2.2.5 Special survey
Scope: Technical
Services
A thorough inspection of all accessible components such as
mooring, structural components and cargo transfer system. Class DDE
surveyor attendance required.
Frequency:
The survey shall be conducted after all large magnitude storm (close
to 100 year storm survival condition) or any suspected collision or
major structural damage.
5.3 Cargo Hoses

5.3.1 Hydrotest of new / used hose
Scope: Technical
Services
After assembly at the hose shed, the hose string to be leak tested.
Upon connection / installation at site, whole system to be
hydrotested at maximum working pressure.
Frequency:
The test shall be carried out prior to installation but subject to hoses
have been in storage for more than one year.
Page 13
Responsible
Parties
5.3.2 Post service inspection
Scope: Technical
Services
Used hoses to be cleaned, visually inspected, hydrotested, vacuum
tested and electrical continuity checked to determine whether the
hose should be retired from or continued in service. Any damage
shall be replaced or withdrawn from use for further examination. Any
minor defect shall be repaired. Major defect such as kink, on the
hose will be cause for rejection.
Frequency:
The above inspection shall be conducted when hose is taken out

from service or during every changeout.
5.3.3 Submarine hose inspection
Scope: Technical
Services
Examination of the hose on the outer surface and at the end of
couplings and joints for kinked or damage sections which could be DDE
caused by contact with anchor chain and crossed lines. Also
examine any traces of oil seepage from the hose flange areas.
Frequency:
The above inspection shall be conducted annually in conjunction

with SBM Below Water Survey or any subsea structural survey in
the vicinity.
5.3.4 Pre-berthing inspection
Scope: Assets
Visual inspection of each floating hose string to ascertain if damage

has occurred by contact with other vessels, crossed lined, possible
kinking, oil seepage, etc.
Frequency:
The above inspection shall be conducted based on tanker schedule

but not exceeding weekly and prior to connection to tanker manifold.
Page 14
Responsible
Parties
5.4 Mooring Buoy
5.4.1 Annual survey
Scope: Technical
Services
External and internal physical inspection of the buoy structure
including its appendages, accessories and fittings for sign of
corrosion or defect. Also, cathodic protection system and
navigational aids shall be inspected.
Frequency:
The above survey shall be conducted annually in conjunction with

any other subsea structural inspection in the vicinity.
5.4.2 Special periodical survey
Scope: Technical
Services
In additional to the requirement of annual survey, buoy body to be
cleaned / refurbished and sacrificial anodes replaced. Examination
of anchor chains and related fittings for sign of wear or corrosion. If
refurbishment is necessary, the whole buoy structure shall be
blasted and painted accordingly.
Frequency:
The above survey shall be conducted every five years.
5.4.3 Special Survey
Scope: Technical
Services
Thorough internal / external inspection of the buoy structure and its
component and accessories. DDE
Frequency:
The above survey shall be conducted after severe / major storm or

any suspected collision or major structural damage as
recommended in survey report.
Page 15
Responsible
Parties
Major problems / damage identified during inspection will be referred Technical

urgently to the relevant technical services section who will conduct Services
the structural integrity review and recommend next course of action.
DDE
Data shall be reviewed and assessed timely, remedial actions shall
be taken based on criticality of anomaly.
Trends from sequential data, if available, shall be monitored for

future plans.
7 MAINTENANCE
7.1 Floating Storage And Offloading
7.1.1 General maintenance
Scope: Technical
Services
For above water, maintenance painting or minor rectification to be
carried out on the FSO's hull, structural and deck plating / house. DDE
For underwater portion, at least 50% of the entire hull bottom and all
sea chests to be cleaned by divers.
All sea valves shall be cleaned and inspected externally and from
inside of FSO in the machinery room.
Frequency:
The maintenance shall be condition-based and conducted every five

years in conjunction with UWILD Survey for underwater portion.
Page 16
Responsible
Parties
7.2 Single Buoy Mooring (SBM)
7.2.1.1 During installation acceptance survey
Scope: Technical
Services
Both above water and underwater structural deficiencies identified
by the Installation contractor. Maintenance work include debris DCE
removal, bolts / nuts tightening, repair, painting damage repair,
missing anodes installation, support of unsupported spans of
pipelines, etc.
Frequency:
The maintenance shall be done when required, as recommended in

the Survey report.
7.2.1.2 During periodical survey
Above water Technical

Services
Scope:
Remedial painting, replacement / repair of mooring equipment,

mooring hawser, floating hose and navigation aids.
Frequency:
The maintenance shall be carried out depending on monthly or

preberthing inspection report.
Underwater
Scope:
The underwater maintenance work will be as identified/found during

the Below Water Periodical Survey (see Section 5.8.4.2.1.2).
Frequency:
The maintenance shall be done as required, based on the survey

report recommendation.
Page 17
Responsible
Parties
7.2.1.3 During special survey
Scope: Technical
Maintenance work include rectification of leakage, rupture hoses, Services
non-operational PLEM system, compartment flooding, subsea
configuration and anchor chain angle discrepancies. During initial DDE
tanker loading, maintenance work may include the opening of valves
or leak investigation.
Frequency:
The survey shall be carried out as required depending on extend of
anomalies.
7.2.2 Hose change-out
Scope: Technical
Services
All hoses including accessories shall be changed out. Each removed
hose shall be cleaned, inspected, tested, repaired (if any) and
restored or disposed of. Prior to recommissioning, whole system to
be hydrotested.
Frequency:
The change-out shall be carried out condition based but not

exceeding five years.
7.2.3 Body overhauls
Scope: Technical
Services
The buoy body will be removed from site and overhauled in
dry-dock. Replacement of expansion joints, sacrificial anodes and
hose string as required. Anchor, chain and connection shall be
checked. Ensure proper tension of chain after reinstallation and
whole system shall be hydrotested before startup. Whole buoy
structure shall be refurbished / painted prior to returning it to site.
Frequency:
The body overhaul shall be done condition-based but not exceeding

10 years.
Page 18
Responsible
Parties
7.3 Single Point Turret (SPT)
Scope: Technical
Services
Any defect, damage or anomalies found during the above and below
water surveys to be rectified accordingly. DDE
Frequency:
The general maintenance as and when required based on the

survey report recommendation.
7.4 Cargo Hoses

7.4.1 Change-out and storage
Scope: Technical
Services
All used hoses to be cleaned, disassembled, inspected, repair (if
any) and restored. All hoses to be stored in a dedicated hose shed
preferably with testing facilities to prolong their service life.
Frequency
The above shall be done on condition-based but not exceeding five

years.
7.5 Mooring Buoy

Scope: Technical
Services
Any structural damage, sign of corrosion, depleted anodes shall be
rectified and replaced accordingly. Buoy body shall be refurbished /
painted every five years or condition based.
Frequency:
The general maintenance as required, determined by survey report,

in conjunction with any subsea structural survey in vicinity.
Page 19
Responsible
Parties
8 DOCUMENTATION
All inspection and maintenance activities shall be clearly and Technical

concisely documented according to the relevant provisions of the Services
procedure documents. A complete and updated record of the
inspection and maintenance reports shall be maintained, using Assets
software tools such as IDAMS and MCS for easy data storage,
retrieval and analysis. DDE
The documentation shall be continuously updated and subjected to

annual review.
Page 20
Subsurface Main Facilities Rev. 1 December 2000
Section 11
SUBSURFACE MAIN FACILITIES
Contents
Paragraph Page

4.1 Subsea Wellheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1.1 On-line wellheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1.2 Redundant wellheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Wellheads and X-Mas Tree (including assemblies) . . . . . . . . . . . . . . . . . . . . 3
4.2.1 Post installation survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2.2 Routine inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2.3 Leak and functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2.4 Internal visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Production Tubings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.1 Caliper survey for oil producers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.2 Caliper survey for gas producers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.3 Sand production monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Downhole Sub-Surface Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4.1 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.5 Special Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5.1 Sand Production Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Caliper Survey Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 Subsea Wellheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 Wellheads and X-Mas Trees (Including Assemblies) . . . . . . . . . . . . . . . . . . 7
6.2.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3 Downhole Sub-Surface Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3.1 Change-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3.2 Valves servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Page 1
Responsible
Parties
maintenance of all sub-surface facilities within Carigali. The
inspection, tests and maintenance shall establish a continuing level
of safe operating conditions and also serve to monitor possible
deterioration of equipment; they shall also provide information upon
which decisions regarding maintenance or other remedial work shall
be made to ensure adequate safety and availability for operations
and installation.


particular section:
API 6A "Specification for Wellhead Equipment"
API 14D "Specification for Wellhead Surface Safety Valves

and Underwater Safety Valves for Offshore Services"
PCSB BDO Report BPT/034/05/91 " Sand Production

Monitoring"
Vendor-provided manuals and Maintenance Manuals for

wellhead Equipment.
An Inspection and Maintenance program for all sub-surface facilities Technical

shall be sheduled for one year look ahead period. The plan shall Services
also take into consideration all previous relevant inspection data and
analysis. Assets
Suitable database system for automatic generation of inspection or

maintenance work orders shall be in place.
The plan shall be reviewed and updated annually.
Page 2
Responsible
Parties
4.1 Subsea Wellheads
4.1.1 On-line wellheads
Scope :
Technical
The scope shall include a close visual examination on all types of Services
sub-sea wellheads and accessories, to check for damages,
leakages, corrosion and any other anomalies.
Frequency:
The facilities are not available within Carigali presently; however, in

the the future the IM shall be carried out as per the vendor's
recommendation.
4.1.2 Redundant wellheads
Scope : Technical
Services
The inspection shall be carried out on sub-sea well head completion
for damages, corrosion, leakages and any other
anomalies.
Frequency :
This inspection shall not exceed 2 1/2 years and shall be carried out
in conjunction with any subsea inspection in the vicinity.
4.2 Wellheads and X-Mas Tree (including assemblies)

4.2.1 Post installation survey
Scope :
DDR
In the above survey, the equipment shall be subjected to a thorough
visual inspection for physical damage and leaks. Pressure tests
should be conducted to ensure compliance to equipment operating
specifications. All safety-related items shall be inspected.
Frequency:
This survey shall be carried out after installation and prior to

handover to Operations.
Page 3
Responsible
Parties
4.2.2 Routine inspection
Scope :
Assets
The Routine Inspection shall include an external visual inspection for
physical damages / corrosion and leaks, of the wellhead and its
associated pipeworks and seals.
Frequency :
This inspection shall be carried out daily for a manned platform;

daily or weekly (whichever is reasonably practical) for unmanned
platforms.
4.2.3 Leak and functional test
Scope :
Assets
Leak and functional tests to be carried out on all X-mas tree
manually operated valves.
Frequency :
This inspection shall be carried out every three months.
4.2.4 Internal visual inspection
Scope : Technical
Services
The above shall be conducted to check for internal physical
damages. DDE
Frequency :
It shall be undertaken whenever, the opportunity arises; it generally

takes place when the wellhead is dismantled from the tubing head
spool during well repair/workover.
Page 4
Responsible
Parties
4.3 Production Tubings
4.3.1 Caliper survey for oil producers
Scope : Technical
Services
This survey shall be conducted on selected wells to maintain a
record of the corrosion/erosion status of the downhole tubing. The
basis of selection is as follows: any well with High Water Cut
(HWC) or H2S or CO2 present in the gas phase or those wells which
are known to suffer from sand erosion.
Frequency :
The survey shall be conducted on a yearly basis and more

frequently in cases where the corrosion/erosion rate in such wells
are found to be significant.
4.3.2 Caliper survey for gas producers
Scope :
Technical
This survey shall be conducted on selected wells to determine the Services
corrosion/erosion status of the downhole tubing.
Frequency :
The frequency of the survey depends on the tubing material:
every 12 to 18 months for carbon/low alloy steel.
every three years for the stinger/tail sections made with AISI
420 (13% Cr) steel but fitted with 9% Cr, 1%Mo accessories.
4.3.3 Sand production monitoring
Scope :
Assets
This monitoring shall involve sand sampling using PETRONAS
approved industry techniques, eg. SSB PCL TM/C3-90. The severity
of the sand production shall depend on the sand production level.
Page 5
Responsible
Parties
Frequency :
Assets
Class 1 (low risk) - monthly
Class 2 (medium risk) - 2 weekly
Class 3 (high risk) - weekly
For detailed classification of the sand production level refer to PCSB

BDO Report BPT/034/05/91.e.g 15 pptb is the cut-off figure for sand
production limit.
4.4 Downhole Sub-Surface Safety Valves

4.4.1 Functional test
Scope: Assets
The Functional Test shall be carried out for all types of subsurface
safety valves excluding the Tubing Retrievable Surface Control
Sub-Surface Safety Valve (TRSCSSV).
Frequency :
The test shall be conducted monthly for the first three months after
installations and subsequently once every 6 months.
4.5 Special Survey
Scope : Technical
Services
The Special Survey shall be performed to inspect the subsurface
facilities to determine any physical damage for reported accidents.
Frequency :
This survey shall be carried out, when required.
Page 6
Responsible
Parties
5.1 Sand Production Data Analysis
The above analysis shall be carried out timely to determine criticality Technical
of sand production. The analysis results shall be used to decide on Services
continued safe operation of the well.
5.2 Caliper Survey Data Analysis
Timely assessment of data (which is captured in IDAMS) shall be Technical

carried out to determine the internal corrosion condition of the Services
production tubings.
6 MAINTENANCE
6.1 Subsea Wellheads
Maintenance shall be carried out on all sub-sea wellheads and its Technical
accessories. Based on the inspection results, the safety aspect of Services
the wellhead shall be considered. Vendor recommendations shall
decide whether the wellhead should still be on line.
Frequency :
The maintenance shall condition-based, i.e. based on inspection
results, analysis and vendor's recommendation.
6.2 Wellheads and X-Mas Trees (Including Assemblies)

6.2.1 Preventive Maintenance
Scope: Assets
The above maintenance shall include injected a sealing compound

into the valves. Grease/lubricate valves and valve stems.
Frequency :
The above maintenance shall be carried out every three months.
Page 7
Responsible
Parties
6.3 Downhole Sub-Surface Safety Valves
6.3.1 Change-out
Scope: Technical
Services
All types of wireline sub-surface safety valves excluding the
TRCSSV shall be changed-out where appropriate.
Frequency :
This shall be based on the outcome of the functional test or every 2

years, whichever is earlier.
6.3.2 Valves servicing
Scope: Technical
Services
All Surface Control Sub-Surface Safety Valve (SCSSV) shall be
serviced and redressed in the workshop before being put back into
service.
Frequency:
This shall be carried out following the valve change-out.
7 DOCUMENTATION
All sub-surface facilities inspection, testing and service records shall Assets
be maintained and updated at the site/base office. These records
shall be updated timely and kept in active filing for a period of three
years.
For Internal Corrosion Monitoring i.e for Caliper Survey, all data
shall be captured and continuously updated using a suitable
database such as IDAMS for storage, easy retrieval and analysis.
Page 8

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MY ALL M 04 001 (V1)

Rev. 1 December 2000

PETRONAS CARIGALI SDN BHD

INSPECTION AND MAINTENANCE GUIDELINES

Appendices Appendix 1 Hierarchy Of Documents In PETRONAS

PETRONAS CARIGALI SDN BHD Preliminary

Authority for original issue

Issue of this document has been formally approved by:

The following person has been assigned as the document

This document contains proprietary information belonging to

PETRONAS CARIGALI SDN BHD Preliminary

No. DIVISION Department/ DESIGNATION Copy

PETRONAS CARIGALI SDN BHD Preliminary

No. DIVISION Department/ DESIGNATION Copy

PETRONAS CARIGALI SDN BHD Preliminary

Revision No. Date Description Approved by:

0 25/04/97 Original issue COO

Doc. Rev. Page No. Date Approved Remarks

0 Main Table of July 1998 COO Addition of CIMG Implementation

0 Section 2 Page 04. July 1998 COO Addition of CIMG Implementation

PETRONAS CARIGALI SDN BHD Preliminary

The PCSB Inspection and Maintenance Guidelines (CIMG) is a document providing a

This is a controlled document and to be revised and updated as changes in regulations or

MOHAMAD JOHARI DASRI

PETRONAS CARIGALI SDN BHD Preliminary

Abbreviations and Acronyms

ABS American Bureau of Shipping

PETRONAS CARIGALI SDN BHD Preliminary

Company PETRONAS PCSB Sdn. Bhd.

PETRONAS CARIGALI SDN BHD Preliminary

Fluid Any gas or liquid

Inspection Visual assessment, data gathering, measurement, testing and analysis to

Visual assessment, testing and measurement to evaluate workmanship or

Maintenance Execution of all activities identified during inspection to retain, restore or

Reliability Centred A structured procedure to optimise expenditures by evaluating maintenance

PETRONAS CARIGALI SDN BHD Preliminary

Telecommunication Include auxiliary radio systems, switching equipment, PETRONAS Wide

PETRONAS CARIGALI SDN BHD Preliminary

PETRONAS CARIGALI SDN BHD Preliminary

3 SCOPE AND LAYOUT ............................................... 3

4 INSPECTION AND MAINTENANCE STRATEGY . . . . . . . . . . . . . . . . . . . . . . . . 4

PETRONAS CARIGALI SDN BHD SECTION 1

The objectives of this CIMG are:

 To promote the application of Reliability Based Maintenance (RBM) and Condition

 To improve effectiveness in IM planning and performance assessment.

PETRONAS CARIGALI SDN BHD SECTION 1

3 SCOPE AND LAYOUT

The body of this CIMG is divided into the following sections:

(1) Offshore Structures

(2) Pipelines and Risers

(3) Piping and Flowlines

(4) Pressure Vessels and Steam Boilers

(5) Major Rotating Equipment

(6) Storage Tanks

(7) Cranes and Lifting Equipment

(8) Export and Support Facilities

(9) Subsurface Main Facilities

(10) Safety Devices and Systems

To promote the application of Reliability Based Maintenance (RBM) and Condition

To improve effectiveness in IM planning and performance assessment.

References and Guidelines

Inspection and Maintenance Plan

Inspection Scope and Frequency

Assessment and Recommendation

The period between inspections is determined on the basis of statutory requirement,

Execution of inspection is done on a timely manner utilising efficient and

The scope of maintenance is planned and executed to be conditional upon the

To use advances in technology in inspection and maintenance to Carigali's

Optimisation utilisation of available resources through better planning and execution

Requirements set by local or Malaysian law governing the installation and

Robustness of the facility design

Availability of standby unit or back-ups

Reliability of the installed facilities

Exposure to risks which results in loss of people, property, process or damaging

Latest inspection findings and data analysis results

Latest maintenance records

API RP2A - Recommended Practice for Planning, Designing and

Lloyds Register of Shipping Guidelines.

DNV Rules for Offshore Structures.

ANSI / ASME Codes.

AWS D1.1 Structural Welding Codes.

Scope: A visual assessment shall be conducted to determine physical Technical