Inspection & Integrity UEC15

Date: 22/11/2008 FROM: TO: COPY: Subject: UEC152 OSO64, OSO61 UEC15, OSO6 On plot Inspection Plan 2009

I. Objective Provide the On plot piping inspection plan details for 2009 including premises and approach adopted II. General Premises: PACER current algorithm requires inspecting all the tags each 4-5 years approximately producing a very frequent inspection program. This approach is considerably more conservative than Owner/User Code such as API570 and requires extensive inspection activities to complete it In order to prioritise the scope of the inspection the following cleansing exercise was adopted: Raw data retrieve from PACER including overdue inspection (31/12/2009) for RI and Unknown status for BL CRA will be removed from the plan Criticality from PACER and Remnant life was used to reduce/optimise the inspection plan Tags with keypoint below the MAT and RL less than 5 years were excluded. Further detailed assessment will be done to establish needs for replacement Tags more than 10 years life and previously inspected less than 5 years will not inspected them at this moment Prioritise according size, rating and service for Unknown/Baseline Inspection piping III. Re-Inspection Plan for On-plot piping A total number of 2866 tags containing a total according PACER Plan adjusted require 431 tags and 8942 keypoints. Distribution per area is shown below Original Plan Area Nimr Marmul Bahja Rima N Tags 888 1075 518 385 2866 Keypoints 33735 38679 24524 12534 109472

of 109472 keypoints required inspection

Plan Adjusted N Tags 94 186 60 91 431 Keypoints 1636 4070 954 2282 8942

IV. Baseline Inspection According PACER below is presented the number of unknown piping per Area Area BAHJA MARMUL NIMR RIMA Unknown [live] 303 326 691 55 1375

In order to prioritise the following criteria was adopted Instrument air piping, CRA and piping internally lined or coated were removed from the plan Rating 150 # and Small Bore piping SBP (<=2 OD) will not be inspected. SBP includes secondary piping that can be isolated from primary piping systems Priorities will based size and rating 1. Piping greater then SBP and >300 # flange rating, priority 1 2. SBP and grater than 300 #, priority 2 3. Piping greater than SBP and <= 300#, priority 3 4. Piping with missing information to do the prioritisation will be assumed priority 3
Unknown Original Plan Plan Adjusted 303 326 691 55 1375 115 163 284 42 604

Area BAHJA MARMUL NIMR RIMA

Station BAHJA MARMUL NIMR RIMA Grand Total

P1 29 12 36 1 78

P2 12 2 36 50

P3 73 149 212 41 475

Grand Total 115 163 284 42 604

V. Guideline Inspection for Insulated piping An important number of tags in unknown condition are insulated piping. In order to improve the evaluation of corrosion under insulation in the piping system the following guideline will be followed 1. Create ISO, most of the insulated tags in Unknown condition do not have isometrics 2. External visual inspections to assess for potential CUI is also to evaluate insulation condition 3. The results of the visual inspection should be documented to facilitate follow-up inspections per tags. Typical areas more susceptible to CUI including: a. All penetrations or breaches in the insulation jacketing systems, such as: Deadlegs (vents, drains, and other similar items). Pipe hangers and other supports. Valves and fittings (irregular insulation surfaces). Bolted-on pipe shoes. Steam tracer tubing penetrations. b. Termination of insulation at flanges and other piping components. c. Damaged or missing insulation jacketing. d. Insulation jacketing seams located on the top of horizontal piping or improperly lapped or sealed insulation jacketing. e. Termination of insulation in a vertical pipe. f. Caulking that has hardened, has separated, or is missing. g. Bulges or staining of the insulation or jacketing system or missing bands. (Bulges may indicate corrosion product buildup.)

h. Low points in piping systems that have a known breach in the insulation system, including low points in long unsupported piping runs. 4. Insulation removal and visual inspection is required for this inspection at damaged or suspect locations.. If the inspection of the damaged or suspect areas has located significant CUI, additional areas should be inspected and, where warranted, up to 100 percent of the circuit should be inspected. 5. In areas where insulation is removed UT records should be taken and recorded properly in areas with and without corrosion under insulation is noticed VI. Guideline for Inspection of buried piping An important number of piping in unknown Inspection are buried process piping. Since the inspection is hindered by the inaccessibility of the affected areas of the piping. Close potential Interval survey, excavation, Soil corrosivity survey , leak test require some additional coordination the above-grade visual surveillance will be adopted In order to collect some information in reference to condition the following approach is suggested: 1. Create ISO, most of the insulated tags in Unknown condition do not have isometrics 2. Conduct Above -Grade Visual Surveillance-TIPS: Indications of leaks in buried piping may include a change in the surface contour of the ground, discoloration of the soil, softening of paving asphalt, pool formation, bubbling water puddles, or noticeable odor. Surveying the route of buried piping is one method of identifying problem areas. The results of the visual inspection should be documented to facilitate follow-up inspections per tags. 3. In key point located upstream of the buried piping some UT data are recommended to assess internal corrosion rate. 4. Especial attention shoud be given to the Soil-to-Air Interface. Inspection at grade should check for coating damage, bare pipe, and pit depth measurements. If significant corrosion is noted, thickness measurements and excavation may be required to assess whether the corrosion is localized to the S/A interface or may be more pervasive to the buried system. Thickness readings at S/A interfaces may expose the metal and accelerate corrosion if coatings and wrappings are not properly restored. 5. Excavation is required only if there is evidence of coating or wrapping damage. If the buried piping is uncoated at grade, consideration should be given to excavating 6 inches to 12 inches (150 mm to 300 mm) deep to assess the potential for hidden damage. 6. At concrete-to-air and asphalt-to-air interfaces of buried piping the inspector should look for evidence that the caulking or seal at the interface has deteriorated and allowed moisture ingress. If such a condition exists on piping systems over it may be necessary to inspect for corrosion beneath the surface before resealing the joint.

VII. Annexes Re-Inspection Plan 2009 onplot RI Nimr.xls 2009 onplot RI Bahja Rima.xls 2009 onplot RI Marmul.xls Baseline Plan 2009 onplot Baseline South.xls