Baseline Thickness Measurement Procedure

BASELINE THICKNESS MEASUREMENT PROCEDURE
MINA ABDULLAH REFINERY
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OA 17-06-15 Issued for Review BBU CM MIJ
Rev. Date Description Originator Checked By Approved By
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Kuwait National Petroleum Company (K.S.C.)
Clean Fuels Project
Kuwait
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Petrofac ~ •11l1~H !1• A

Petrofac I Samsung I CB&I
PSCJ Job No. Jl-2025 1 SAMSUNG
ENGINEERING
Subcontractor Doc. No.
CONSOLIDATED CONTRACTORS COMPANY (CCC)

..
llC/BLTP/03C/CFP/CCC
--
CONTRACT NO. CONTRACTOR JOB NO. DOCUMENT NO. REV
Jl/2025/06-01 Jl-2025 - OA
Kuwait National Petroleum Company
(K.S.C) llC/UT/03C/CFP/CCC
BASELINE THICKNESS
Clean Fuels Project REV. OA, 17-JUNE-15
MEASUREMENT PROCEDURE
KNPC Contract No. CFP/EPC/0054-MAB1 Page 2of18
PSCJ Job No. Jl-2025
Revision Record Sheet

NOTES
Revisions after Rev. OA are denoted by a vertical line in the left hand margin against the
revised text, with the revision number displayed next to the revision line as shown on the
left.
i) First submission OA, OB, OC .. ..

ii) Approved by PSCJ , then revision cycle will start from 01 , 02, 03, 04 .. ..
iii) Approved document with Hold, then revision cycle will start from R1, R2, R3 .... .
iv) Approved by PSCJ/KNPC, then revision cycle will start from S1 , S2 , S3, S4 .. ..
Record of Revisions
Rev. No. Page/Section Description

OA All First issue for Review
List of Holds
Page/Section Description
BASELINE THICKNESS
TABLE OF CONTENTS
SECTION TITLE PAGE
1.0 PURPOSE 4
2.0 SCOPE 4
3.0 REFERENCES 4
4.0 ABBREVIATIONS 4
5.0 PROCEDURE 5
5.1 PERSONNEL QUALIFICATION 5

5.2 EQUIPMENT 5
5.3 COUPLANT 6
5.4 CALIBRATION 6
5.5 SURFACE CONDITION 6

5.6 EXAMINATION REQUIREMENTS 6
5.7 THICKNESS MEASUREMENT 7
REQUIREMENTS
5.8 THICKNESS MEASUREMENT 17

LOCATIONS
5.9 INSPECTION POINTS 17

DOCUMENTATION
5.10 17
5.11 18
6.0 SAFETY 18
7.0 REFERENCE ATTACHMENTS 18
A INTIU!X
BASELINE THICKNESS
1.0 PURPOSE
The purpose of this procedure is to provide the specific requirements to perform

the Baseline Thickness Measurement for piping, equipment and tanks to meet
the specific contractual specifications and requirements of the Project - Clean
Fuels Project (CFP), MAB Package 1
2.0 SCOPE
This procedure describes the minimum requirements for the thickness survey of
materials which shall be performed on painted surface after the pressure test by
manual ultrasonic pulse echo contact method. This scope includes the methods
of calibration, evaluation and reporting. This document has specific reference to
the Project - Clean Fuels Project (CFP), MAB Package 1
3.0 REFERENCES
ASME Sec V - Non-Destructive Examination
ASNT-SNT-TC1A - Recommended Practice for Non- Destructive
Testing Personnel
ASTM E 1316 - Terminology for Nondestructive Examination
ASTM E 797 - Standard Practice for Measuring Thickness by
Manual Ultrasonic Pulso Echo Contact Metod.
Shell DEP 31.38.01 .31 Gen. - Shop & Field Fabrication Of Piping .
31 .38.01.31-P6000CFP-OOO-PV - Proj. Variation to SHELL
DEP31.38.01.31,Shop and Field
Fabrication of Piping
UOP 8-11-15 Piping Standard Specification
4.0 ABBREVIATIONS
COMPANY Kuwait National Petroleum Company ( K.S.C) (KNPC)

MAB-1 Mina Abdullah Refinery- Package 1
EPC CONTRACTOR : Petrofac International Ltd, Samsung Engg, CB&I (
PSCJ)
PMC Foster Wheeler Energy Limited, UK
SUB-CONTRACTOR : Consolidated Contractors Company (CCC)
ITP Inspection Test Plan
NOE Nondestructive Examination
4.1 DETAILS OF THE PROJECT

• Name of the Project : Clean Fuels Project (CFP)
BASELINE THICKNESS
• Company Project Number :CFP/EPC/0054/MAB-1

• Commencement Date : 13th April, 2014
4.2 DEFINITION
• COMPANY TEAM is the integrated Project Management Team
comprising of KNPC and Foster Wheeler employees.
• Contractor Project Team is the "Petrofac Samsung Engineering CB&I

JV (PSCJ) entrusted with execution of the PROJECT.
5.0 PROCEDURE
5. 1 PERSONNEL QUALIFICATIONS
5.1 .1 Personnel involved in this testing shall be qualified to the requirements of
ASNT-SNT-TC 1A.
5.1.2 NDT UT Level II personnel shall perform the test.
5.1.3 Qualification records of certified personnel shall be submitted to the client
for approval prior to start the Thickness Survey.
5. 2 EQUIPMENT
5.2.1 Basic Unit

The basic electronic instrument pulsed ultrasonic testing contains a source
of voltage spikes (to activate the sound source, i.e. the pulser) and a display
mechanism that permits interpretation of received ultrasonic
impulses.Ultrasonic flaw detectors with A scan display and direct thickness
readout or only direct thickness readout instruments shall be used .The
equipment shall be with an accuracy of minimum ±0.1mm.
5.2.2 Probe
A probe, as applied to ultrasonic testing is the means by which electrical
energy is converted into acoustic energy and back again. The material used
to convert electrical energy into acoustic energy and vise versa is called a
crystal. Depending on test requirements, different materials of different
properties are used in the probes.
5.2.3 Type of Probes
A Normal probe 2.5 - 7.5 MHz & 5-10 mm diameter or curved probes to
suit the curvature of the pipe surface (for small bore pipes)
BASELINE THICKNESS
5.3 COUPLANT
5.3.1 A liquid or paste is used to couple the probe and the test surface since the
ultrasonic sound waves travel poorly in air and not at all in vacuum.
5.3.2 Couplants are selected based on their properties of wetability, viscosity, low
cost, removability, non-corrosive and non-toxic properties.
5.3.3 Surface finish, surface orientation and temperature are some of the factors
influencing selection of couplant.
5.3.4 Couplants used on nickel base alloys shall not contain more than 250ppm of
sulfur.
5.3.5 Couplants used on austenitic stainless steel or titanium shall not contain
more than 250 ppm of halides (chlorides plus fluorides)
5.4 CALIBRATION
The basic unit shall be calibrated yearly or after any major repair/service
done to the equipment and records shall be provided to the company
5. 5 SURFACE CONDITION
5.5.1 All surface shall be clean and free of scale,dirt,grease or other foreign
material that could interfere with interpretation of examination results .If
painting or coating is present on the thickness survey location then
thickness survey shall be done using an instrument which is capable of
measuring & displaying the metal thickness excluding the thickness of
internal and extenal coating.
5. 6 EXAMINATION REQUIREMENTS
5.6.1 Place the search unit on a standardization block of known thickness from the
same material group as the material to be measured with suitable couplant
and adjust the instrument controls (material standardization, velocity) until the
display presents the appropriate thickness reading.
5.6.2 Place the search unit on the part where thickness to be measured and take
the reading (mm) from the basic unit display.
5.6.3 If flaw detectors are used the scanning speed shall not be more than 100
mm/sec.
BASELINE THICKNESS
KNPC Contract No. CFP/EPC/0054-MAB1 Page 7of 18
5. 7 THICKNESS MEASUREMENT REQUIREMENTS
a) FOR PIPING
All the pipes, fittings shall be subject to thickness verification . Number of
locations and area of examination shall be as below
All the piping with diameter 2" and above requires thickness survey.
However for highly corrosive services thickness survey shall be considered
up to 1 1/2 "diameter.
5.7.1 In case of 45° elbows , thickness survey requirements are similar to that of
90° elbows.
For underground piping , each length of pipe/ fitting one spot thickness
check is required .
5.7.2 Straight Pipe (Length Grater than 60 Inch):
5. 7 .2.1 One Monitoring point ( at 10 meters approx. interval for Inside battery
limit and 50 meters interval for outside battery limit at top, bottom, left and
right ( 3,6,9,12 O'clock) positions).
Thickness measurements shall preferably be made at upstream and
downstream of the instrument connections such as control valves,
instrument, orifice etc ... as per the details given for straight pipe/ fittings as
applicable.
--·0 -+---
2 3
5.7.3 Pipe Fittings (90° I 180° Elbow. Reducers I Expander. Tee):

Thickness measurement shall be made as per the details on the sketches
given below:
BASELINE THICKNESS
FLOW
FLOW
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ECCENTRIC A.NO CONCEl'fTRJC REIXJCffiS
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ALL TCST POINTS - N,S,C,W,T,B
All TeST POlNTS - N,S,E",W,T,B
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3
5.7.4 Mitre Bends & End Caps:

Thickness measurements shall be made as per the details on the sketches
given below:
BASELINE THICKNESS
~ 1:) 2
3
ALL S IZ ES
9
ALL SIZ ES
5.7.5 Exemptions on thickess Survey:

1. Cut pipes with length less than 60 inch
2. Small diameter piping for package items ( Eg . RO plant, Nitogen
Generation plant, Lube oil skids Etc. )
b) FOR EQUIPMENTS
5.7.6 Vessels (Drum) : initial thickness reading shall be taken as per the below
figure 1a & 1 b.
·yERJ:l©·AL ·0YE$SEL {DRDlYq± HtkiNE:S5,; :tvfo'NiXCi)Rl1'.9 ~ eQTNtt@ :;(;'f.¥ffl( )
Figure la
BASELINE THICKNESS
Figure 1b
5.7.7 Towers (Drum) initial thickness reading shall be taken as per the below
figure.2
Figure 2
lJ. .
BASELINE THICKNESS
KNPC Contract No. CFP/EPC/0054-MAB1 Page 11 of 18
5.7.8 Reactors : initial thickness reading shall be taken as per given figure .3
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Figure 3
BASELINE THICKNESS
5.7.9 Heat Exchangers (Fin Fan Coolers & Shell & Tube Type) : initial thickness
reading shall be taken as per given figure 4a & 4b
FIN FAN THICKNESS MONITORING POINTS (IYP.)

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I Figure 4 a
BASELINE THICKNESS
THICKNESS MONITORING PolNTS FOR HEAT EXCHANGER·

[SHELL&. TUBETYPEJ
tfQil.:. 1, .FOURREADINGS AU.MOUND WlU. ~ TN<EN

ro{l ALL ti.Ont.Es OJA 0-a- NOABOW.
FtqATING ljfAD
Figure 4b
INTREC
BASELINE THICKNESS
5.7.10 Heater & Boiler Tubes initial thickness reading shall be taken as per
given figure 5
HEATERPt BOILER TUBES THICKNEs.5 MON!TORING POINTS
Note!
THICKNESS RfAOlNGS SHAU. BETAKEN~ El(H 1\JBE AND BEND AS Pet DETAILS~ ABOVE.
- -----=----------ii Figure 5
A
BASELINE THICKNESS
5. 7.11 Portable Gas Container initial thickness reading shall be taken as per
given figure 6
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Figure 6
BASELINE THICKNESS
c) Storage Tanks
5.7.12 Shell:
• Shell Course 1 (bottom Strake) : 9 readings per plate min .
• Shell Course 2 and above : 3 reading per plate min.
• Shell course 3 & above :
2 readings per plate min . all along the stircase

3 readings per plate min . all along the scafolding at the time of internal
inspection
5.7.13 Fixed Roof:
• Rectangular Plates : 6 readings per plate min.
• Sketch Plates: 3 readings per plate min .
• 10 additiopnal readings, 6 inches on centre, shall be
taken at gauges platform at the outer edge near the
shell-to-roof.
5. 7 .14 Floating Roof:
• Sketch Plates : 3 readings per plate min.
• Pontoon Plates : 2 readings every 10 ft around circum.
5.7.15 Bottom Plates including drain Sump:

• Sketch Plates : 3 readings per plate min.
• Gire. Readings : 2 ft apart, 6 inches from shell
5.7.16 Nozzles: 2 readings min .
d) Other Equipment
5. 7 .17 For equipment other than listed above, thickness survey locations shall be
determined by Contractor and approved by Company.
BASELINE THICKNESS
5.8 THICKNESS MEASURMENT LOCATION LABELS ( TML ) :

Identification labels shall be provided at location where thickness survey is
performed. One of the below models may be selected for this purpose. Any
one of the below models shall be produced or pasted on locations of the
thickness check. Manufacturer recommendation shall be followed fixing the
same. Material shall be free from lead, zinc etc. for stainless steel surface.
5.9 INSPECTION POINT PLUGS FOR INSULATED PIPING,

EQUIPMENT, TANKS
Removable inspection plugs shall be installed on the locations where
thickness survey is being performed in order to enable future thickness
surveys on same locations on insulated piping, equipments and Tanks
without removal of the insulation system.
5.10.1 Cheese Hole Size
Pipe size 8" to 1O" - 3" diameter
Pipe size 1O" and above - 5" diameter
For pipe sizes 6" and below - Cheese holes may be replaced with sleeve
box type removable insulation, like tailor made jackets or preformed
insulation boxes & it shall be suitable for quick removal and reinstallation. All
tailor made jackets shall fit the actual pipe and fitting . Minimum 4' width shall
be provided for box for 1 1/2 " pipe size . Dimension shall be decided
proportionally for higher sizes
5.10.2 Exemptions on Cheese hole requirements :
1. CS and Low alloy steel piping with Hydrocarbon sirvice with wet H2 S (H 2S
content > 50 PPM dissolved H2S in free water)
2. Crude, LPG condensate & Gas lines for Kuwait Oil Company
3. Piping with C- 1/2 Mo material operating above Nelson curve
4. Col Insulated lines.
(K.S.C) llC/UT/OJC/CFP/CCC
BASELINE THICKNESS
5.10 DOCUMENTATION
5.11 .1 The spots where thickness readings were taken shall be marked up on
applicable isometrics with unique number for each of the locations
A,B,C,Ds may be used to represent 0°, 90°,180°,270° and a permanent
marker preferably at 0° location shall be placed on the pipe/fittings for
reference which will be followed by the flow direction and continuous
unique numbers as per line & Isometric number.
5.11 .2 The examination details (Required thickness , isometric drawing reference,
line reference, line size, thickness reading, average thickness reading,
location of measurement, size frequency and type of search unit and
identification of the operator who carried out of each examination etc. )
shall be reported in the format as shown on the attached report formats for
piping (Attachment A) and equipment (Attachment B)
5.11.3 The location of the spots shall be marked up in the hard copy and soft
copy of the isometric drawings. Soft and hard copies of documents shall
be submitted to the company. Autocad software will be used for producing
isometrics.
5.11.4 The thickness data shall be in the form of a spread sheet given against
the unique number assigned for the spots. This shall be in the form of an
excel sheet and both soft and hard copies shall be submitted to the
company.
6.0 SAFETY
6.1 Adequate Personnel Protective Equipment (PPE) shall be provided and

worn when required.
6.2 The area of examination shall have adequate lighting and ventilation.
6.3 Fire and Safety Regulation of client shall be adhered to at all times.
6.4 Manufacturer's recommendations for storage and usage of hazard materials
shall be strictly followed .
6.5 Radiography Safety Procedure specific for the project shall be followed.
7.0 REFERENCE ATTACHMENTS

7.1 Attachment A -Thickness Survey Report -Piping
7.2 Attachment B -Thickness Survey Report -Equipment
INTltl!X
INTERNATIONAL Head Office: East Ahmadi, Block No.6,
INSPECTION Plot No.142, P.O.Box No.296,
Sabahiya, S4573 Kuwait.
CENTRE W .L.L Tel : 23986748, 23988915, 23984391,
Paid Capital 23984389, Fax: 23986749
Email: enqulry@intrexkw.com
KD.250,000/- INTREX Websit e: www.intrexkw .com
THICKNESS REPORT FOR PIPING

QA/QC FORM AT: llC/PS39/12 Rev.O
::lient : Report No. :
Project: Date :
Location : Instrument: :
Line No. Calibration Block :
Procedure Probe Type I Size :
Design Pressure : Couplant :
Max Operationg Pressure Flange Rating :
Max Operationg Temperature : Material :
Pipe Diameter
Pipe Schedule
Nominal thickness
Minimum thickness Required
Drawing No :
THICKNESS READINGS IN "mm"

Location Location Location Location Location Location Location
SL. No. POINT Remarks
1 2 3 4 5 6 7
1
10
11
12
13
14
RESULTS:
Inspected By Witnessed By Reviewed By Client
Name
Sign
Date
ATIACHMENT A t o Doc. No llC/BLTP/03C/CFP/CCC

INTERNATIONAL
INSPECTION
CENTRE W.L.L
Paid Capital KD.250,000/-
INTREX
TIDCKNESS REPORT FOR EQUIPMENTS QA/QC FORMAT: IIC/PS39B/12 Rev.0

Client: Report No:
Equipment No. : Date:
Service: Drawing No.
Material type: Location :
Calibration Block: Equipment:
Design Pressure : Model No:
Max. operating pressure : Couplant:
Max. Operatine: Temperature : Design Temperature:
SHELL NOZZLE RF PADS
Thickness Thickness Thickness
of the of the of the
shell as Minimum Nozzle as Minimum PAD as Minimum
per data Acceptable Actual per data Acceptable Actual per data Acceptable Actual
sheet Thickness Thickness sheet Thickness Thickness sheet Thickness Thickness
Inspected By Witnessed By Reviewed By Client
NAME
SIGN
DATE
ATTACHMENT B to Doc. No IIC/BLTP/03C/CFP/CCC

Baseline Thickness Measurement Procedure

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BASELINE THICKNESS MEASUREMENT PROCEDURE

MINA ABDULLAH REFINERY

Rev. Date Description Originator Checked By Approved By

Petrofac ~ •11l1~H !1• A

Subcontractor Doc. No.

CONSOLIDATED CONTRACTORS COMPANY (CCC)

Revision Record Sheet

i) First submission OA, OB, OC .. ..

Rev. No. Page/Section Description

SECTION TITLE PAGE

5.1 PERSONNEL QUALIFICATION 5

5.5 SURFACE CONDITION 6

5.8 THICKNESS MEASUREMENT 17

5.9 INSPECTION POINTS 17

The purpose of this procedure is to provide the specific requirements to perform

COMPANY Kuwait National Petroleum Company ( K.S.C) (KNPC)

4.1 DETAILS OF THE PROJECT

• Company Project Number :CFP/EPC/0054/MAB-1

• Contractor Project Team is the "Petrofac Samsung Engineering CB&I

5.2.1 Basic Unit

5. 7 THICKNESS MEASUREMENT REQUIREMENTS

5.7.2 Straight Pipe (Length Grater than 60 Inch):

5.7.3 Pipe Fittings (90° I 180° Elbow. Reducers I Expander. Tee):

All TeST POlNTS - N,S,E",W,T,B

5.7.4 Mitre Bends & End Caps:

5.7.5 Exemptions on thickess Survey:

-REAOIQR:: - ~HJ~t;lEa~f!~~~:(lKfl~1'fNl1 ·?Jilf6l{f~ :~f.~)%gre

FIN FAN THICKNESS MONITORING POINTS (IYP.)

Wt» ME Pl.UC PUTt

THICKNESS MONITORING PolNTS FOR HEAT EXCHANGER·

tfQil.:. 1, .FOURREADINGS AU.MOUND WlU. ~ TN<EN

HEATERPt BOILER TUBES THICKNEs.5 MON!TORING POINTS

2 readings per plate min . all along the stircase

5.7.15 Bottom Plates including drain Sump:

5.7.16 Nozzles: 2 readings min .

5.8 THICKNESS MEASURMENT LOCATION LABELS ( TML ) :

5.9 INSPECTION POINT PLUGS FOR INSULATED PIPING,

6.1 Adequate Personnel Protective Equipment (PPE) shall be provided and

7.0 REFERENCE ATTACHMENTS

THICKNESS REPORT FOR PIPING

::lient : Report No. :

Line No. Calibration Block :

Procedure Probe Type I Size :

Design Pressure : Couplant :

Max Operationg Pressure Flange Rating :

Max Operationg Temperature : Material :

Minimum thickness Required

THICKNESS READINGS IN "mm"

Inspected By Witnessed By Reviewed By Client

ATIACHMENT A t o Doc. No llC/BLTP/03C/CFP/CCC

TIDCKNESS REPORT FOR EQUIPMENTS QA/QC FORMAT: IIC/PS39B/12 Rev.0

Inspected By Witnessed By Reviewed By Client

ATTACHMENT B to Doc. No IIC/BLTP/03C/CFP/CCC

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