00-SAIP-71 Plant Inspection Index Document Responsibility: Inspection Department 31 January 2005
Attachment I Sample PII Summary Report.... 6 Attachment II Sample PII Entry Sheet.... 7 Attachment III Sample PII Chart......... 21
Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Scope This SAIP is to provide guidelines for Saudi Aramco Plant Inspection Units (PIUs) and the Inspection Department Engineering Unit (IEU) to periodically conduct scoring of the PIU performance and submit the results to IEU for semi-annual reporting to plant management. Plant inspection index (PII) is to cover performance of all inspection activities as per the listed seventeen (17) measures in the attachment.
References Saudi Aramco Engineering Procedures SAEP-20 SAEP-308 SAEP-309 SAEP-316 SAEP-317 SAEP-318 SAEP-319 SAEP-321 SAEP-322 SAEP-325 SAEP-333 SAEP-343 SAEP-1135 SAEP-1140 SAEP-1142 Equipment Inspection Schedule Operations Inspection Unit Reviews Inspection of Community and Operations Support Facilities Performance Qualification of Coating Personnel Testing and Inspection (T&I) of Shell and Tube Heat Exchangers Pressure Relief Valve Program Authorization for Installation, Deletion and Changes Relief Valves Routine Test, Inspection, Quality Assurance and Regulation Performance Qualification Testing and Certification of Saudi Aramco Welders Performance Qualification Testing and Certification of Saudi Aramco Brazers Inspection Requirements for Pressurized Equipment Cathodic Protection Monitoring Risk-Based Assessment for In-Plant Static Equipment On-Stream Inspection Administration Qualification of Saudi Aramco NDT Personnel Qualification of Non-Saudi Aramco NDT Personnel
Saudi Aramco Inspection Procedures 00-SAIP-06 00-SAIP-07 00-SAIP-12 Pressure Test Requirements Positive Material Identification Requirements Equipment Deficiency Reports
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
00-SAIP-51 00-SAIP-72 00-SAIP-73 00-SAIP-74 00-SAIP-75 00-SAIP-76 00-SAIP-77 00-SAIP-78 00-SAIP-79 01-SAIP-01 01-SAIP-04 3 Objectives 2.1
Electrical Inspection Inspection Involvement in Management of Change Inspection Manning Determination Guidelines Corrosion under Insulation Inspection External Inspection Worksheet Control & Tracking Technical Alert Implementation & Tracking Inspection Records & Filing Assessment Recommendations Tracking System Small Pipes & Nipples Inspection Programs Injection Points Inspection Programs
To measure and monitor the overall performance of the plant inspection units following a predetermined seventeen (17) measures that covers all inspection activities. To identify gaps in the seventeen (17) inspection programs and function that include on-stream-inspection program, the relief valve program, welder tracking system and the equipment inspection schedules. To verify that Saudi Aramco standards and procedures are being properly implemented along with the applicable industry standards. To highlight to plant management gaps in the PIU for timely corrective action.
2.2
2.3 2.4 4
Responsibilities 4.1 The PIU Supervisor shall form a team, two times a year, including representative(s) from other inspection units to measure the performance of his respective unit. The PIU Supervisor shall, with transmittal letter from his Div. head/GS, also send all the performance results supported by all documents if requested to the Inspection Department (ID) to update the respective Unit's performance by June 30th and December 31st. Upon request of the Facility Manager, the ID should spot-check the performance of the respective Inspection Unit.
4.2
4.3
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
4.4 4.5
The IEU shall make the calculation spread sheet available for the PIUs through ID web site and maintain it as required. The IEU shall send the semi-annual PII Report of the PIU to its respective Facility Manager.
Scoring Process 5.1 Every six months (End of June and end of December every year), the Plant Inspection Unit Supervisor shall form a team, including a representative(s) from another Plant Inspection Unit (Sr. Inspector or above), to perform the PII scoring of his respective Unit. The team shall cover the seventeen (17) measures listed in attachment I. The team shall submit the results to the PIU Supervisor with all the documents supporting the Unit's performance calculations. The PIU Supervisor should review and confirm the results with the team prior to submittal to ID/OID. The final calculations of the Unit performance should be available with all supporting documents for possible verification by IEU. IEU/OID can request support documents for verification. Any nonconformance will be returned back to the respective Inspection Unit for correction or clarifications. If all results are accepted by IEU, then the Units performance will be reflected in the PII and forwarded to the PIU plant manager. In each of the 17 measures, there are questions (Attachment II) that need to be answered to calculate the total scoring for that specific measure. Each question is given a maximum score that can be achieved if the Unit is fully meeting the requirement. Some questions are based on a "yes" or "no" answer while others are percentage-based to help clarify the answer (i.e., the experience level of the unit is to be scored based on the given percentages). Questions that are not applicable can be marked with N/A and the program will not consider that specific question in the final calculation (i.e., the rupture disks may not be available at some of the plants in which case the question will not be considered in the total score). Each one of the 17 measures has been given a weight factor based on how important they are to the overall performance of the facility.
5.7 5.8
5.9
5.10
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
5.11
The minimum acceptable PII score shall be set as 80% for the overall and 60% for the individual programs. These levels will be revised based on performance by the PIU units.
Commentary Note: These percentages are based on the results obtained after testing this index on selected PIUs.
5.12
The calculation sheet will automatically calculate the overall performance of the Unit based on the calculated scores of the measures. A chart (attachment III) will be generated reflecting the Unit performance for each one of the 17 measures. The PII scoring sheet can be obtained from the ID website Operations Inspection Division http://id.aramco.com.sa/site/index.asp?Module=OID.
Revision Summary New Saudi Aramco Inspection Procedure.
5.13
31 January 2005
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
#
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Technical Administration Training & Certification Relief Valves Mechanical Inspection
INDICES
Equipment Inspection Schedule On-Stream Inspection Corrosion Control & Monitoring Welding/Repair Inspection Coating Filing/Records Keeping Civil and Structural Inspection Electrical Inspection Nondestructive Testing Operations Management of Change Worksheet & Reporting Management of Recommendations Positive Material Identification
PII 0.6 0.7 1.0 0.8 0.7 0.8 0.7 0.9 0.7 0.8 0.7 0.7 1.0 0.8 0.8 0.5 0.9 13.1 89% 84%
COMMENTS
PLANT INSPECTION INDEX: Reduced PII Due to Incident Related to Inspection Signed by: Plant Inspection Unit Supervisor Signed by:
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
ATTACHMENT II SAMPLE (PII) ENTRY SHEET (Only Shaded Fields are to be filled) XYZ Inspection Unit Jan-Jun, 2005
Actual Score
4 3 1 3 2 4 0 2 2 4
Max Score
Reference Standard
Has the unit had a study of the workload and experience level to decide the number of inspectors and number of supervisors and whenever new plants are added? Based on the above study, does the unit have the proper number of Inspectors, Senior Inspectors and Field Supervisors? Is the Supervision assignment continuous? What is the average experience level in the Unit? Does the Unit have up-to-date written orientation Program for new inspectors? Is the inspection function independent from other organization to prevent influence? Has an incident or unplanned shutdown taken place that was found to be a result of inspection program failure since the last assessment? Does the Inspection Unit participate in all Management plant walkthrough inspections and participate in the review meetings? Does the unit conduct at least monthly safety/communication meetings? Has the unit conducted the annual self assessment? TOTAL FOR TECHNICAL ADMINISTRATION
00-SAIP-73
4 3 4 2 4
00-SAIP-73
Technical Administration
CLPM
2 2 4 35
25
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 4 2 4 3 0 4 2 2
Max Score
Reference Standard
Does the unit have an individual to coordinate inspector training? Is the AJTS training program implemented in the Unit? Is there a 1:4 mentorto-mentee ratio in the unit to verify and sign off tasks? Is there a written schedule for in-house training? Does the Unit have a IDP's for each inspector? Are Aramco and body certification obtained per Job description for all inspectors? Does the unit have a system for regularly informing its inspectors of the revised Standards and procedures? Does the Unit have a tracking system for NDT personnel certification validation? Is the schedule for in-house training followed? Do all inspectors have at least one week inspection training course per year? TOTAL FOR TRAINING AND CERTIFICATION Is a Quality manual for PZV in the PZV shop available and followed? If not has the unit highlighted deficiencies to management? Are all your RVs tested within EIS (i.e. none overdue without approved deviation request per SAP RV System)? Do you physically check Rupture Discs for integrity?
4 4 4 2 4 4 4 4 2 2 34 4
AJTS/Job Description
GI-1809.001
29
4
Relief Valves
4 4
NA
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 4 4 4 4 4
Max Score
Reference Standard
Are internal audits conducted on maintenance shops per schedule? Is physical check conducted on RV after installation and check list filed including correct installation, car sealing, color-coding, etc)? Are mothballed RV properly designated and tracked? Is the testing interval reviewed and adjusted based on service, performance and conditions? Are valves open to atmospheres regularly checked for open drain Is the relief valve coordinator trained in SAP system and operations? Has the relief valve coordinator completed the AJTS for relief valve inspection? TOTAL FOR RELIEF VALVES Are pressure vessels being inspected by API certified inspectors or by inspectors having more than 20 years inspection experience or have completed AJTS requirements? Are all mechanical inspections being done by API/AWS certified inspectors or under their immediate supervision? Is a checklist being utilized when conducting external inspection? Are tanks being inspected by API certified inspectors or by inspectors having more than 20 years inspection experience or have completed AJTS requirements?
4 4 4 4 4 4 36 4
36
4
Mechanical Inspection
AJTS/Job Description
4 4
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
2 4 4 0 4 4 4
Max Score
Reference Standard
Are piping and pipelines being inspected by API certified inspectors or by inspectors having more than 20 years inspection experience or have completed AJTS requirements? Have all inspectors completed the AJTS for assigned mechanical jobs? Is SAEP-325 being followed all the time when inspecting pressurized equipment? Is risk based inspection or prioritization based on SAEP325 being used to optimize mechanical inspections? Are the mechanical inspection tools available to perform the required mechanical inspections (e.g. flash light, pit gauge, hammer, magnet, magnifying glass, etc.) Is the external inspection required by SAEP-20 being performed timely (no overdue)? Is inspection formally informed of maintenance activities such as during OME meetings? TOTAL FOR MECHANICAL INSPECTION Are all pieces of equipment included in the EIS as required SAEP-20? Are deviation requests submitted to the Inspection Department (complete & timely)? Is the discretionary letter for over due equipment issued timely? Do you have a computerized tracking system for EIS with reminding capabilities and can be accessible by Operations and T&I Planning?
4 4 4
4 4 44 4 4 4 3
35
4
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 0 3 NA NA 4 3
Max Score
Reference Standard
Have you completed initial T&I for all new equipment per SAEP-20? Have you complied with the external inspection requirement as per SAEP-20? Is RBA conducted to optimize inspection? Is EIS evaluation for possible adjustments after T&I conducted and documented? Are road crossing inspection & revalidation conducted per EIS? Is a sub-sea pipeline inspection program functional? Are all Operations Support Facilities listed and inspected per EIS and schedule? Are mothballed equipment identified and monitored per SAEP-20 and SAER 2365 ? TOTAL FOR EQUIPMENT INSPECTION SCHEDULE Do you have an individual coordinating the On-Stream Inspection? Do you have a system for verifying OSI data errors within 90 days? Do you have OSI drawings for all equipment and piping in hydrocarbon service or critical service? Does the inspection Unit have a system to ensure modifying OSI isometric drawings when changes are made to plant? Do you have a program for Nipple surveys?
4 4 2 3 4 4 4 3 35 4 4 4 3 4
SAEP-20 SAEP-20 SAEP-20 SAEP-20 SAEP-20 SAEP-20 SAEP20&SAEP309 SAEP-20 , SAER 2365
29
4
On-Stream Inspection
SAEP-1135
0 4
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
NA 4 0 NA 0 3 4 NA 3 4 4 4 4
Max Score
Reference Standard
Do you have chemical injection points and system to monitor them? Are dead legs identified and being monitored? Are all vessels susceptible for Corrosion Under Insulation and fireproofing identified and included for CUI Inspection? Is there a system for Inspecting transition area soil/air interface) and splash zones? Do you perform OSI 6 months prior to T&I? Are all your equipment up-to-date with their TMLs (i.e. No backlog)? Are process piping classified per SAEP-1135? Do you monitor and document heaters in the creep range for metallurgical aging, creep and/or creep cracking? Do you perform thermography for monitoring hot spots and refractory damage where other methods can not produce the needed information? Do you inspect bolts and guy wires for stacks and flares for structural soundness? Have all your new plants had TMLs baseline readings? Is susceptible flare lines periodically checked for fouling to ensure adequacy for emergency relief? Is the OSI computer program currently functioning to analyze the gathered field data? TOTAL FOR ON-STREAM INSPECTION
4 4 4 4 3 4 4 4
SAEP-20
4 4 4 4 57
46
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 3 4 0 4 4 4 3 4 2
Max Score
Reference Standard
Does the unit/division have a corrosion engineer? Or CP specialist for Terminal and Bulk plants? Has the corrosion engineer completed the required 3month training program? Is the CE responsibility defined in the OSI procedure? Is failure analysis conducted on all failures that impact reliability or safety?
4 4 3 4 4
Is there a leak reporting system documenting leaks and failures impacting reliability or safety? Is there a system in place to assure that equipment susceptible to environmental cracking (amine, caustic, wet H2S, deaerators) inspected at appropriate intervals with appropriate NDT method? Do you have a unit-specific corrosion control document (CCDs) or equivalent in place for each of your existing processing units? Do you have effective CP for your Tanks, sub-sea structures and buried piping? Are damage mechanisms other than pitting and general thinning reviewed by a corrosion engineer during set up of the inspection plans? Is the yearly and quarterly schedule as applicable for monitoring the CP system available, implemented and reported? Is the SAEP-333A survey report forms utilized for the CP system survey?
SAEP-325
4 2
SAEP-333 SAEP-333
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 NA
Max Score
Reference Standard
Is the low potential reading and/or the CP system deficiencies reported and tracked? Is the capacity test for the solar system performed every 2 years Is the result of the CP inspection communicated to the inspection Units if done by others? TOTAL FOR CORROSION CONTROL/MONITORING Are all welding jobs inspected by certified welding inspectors?
4 4 4 48 4 4 4 4 4 4 4 24
44
4 4 4 NA 4 4
Welding/Repair Inspection
Is Welder Tracking System installed and updated? Do you enter welder performance in the WTS? Do you repair ASME vessels by certified shops? Are welding inspection tools available? Are shop and field weld inspection covered and roles specified? Is shop electrode ovens and electrode handling process periodically checked, results documented and recommendations followed up? TOTAL FOR WELDING/REPAIR INSPECTION
SAES-W10/11/12/13
24
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 4 0 4 4
Max Score
Reference Standard
Are blasters and painters certified by the Unit or are qualifications of contractor personnel (blasters and painters) checked by Unit?
Coating Inspection
Are all coating inspection performed by certified inspectors? Is holiday testing conducted on all critical coating? Are major and premature coating failures investigated and results documented? Are coating jobs QA forms filled in and filed? Are sufficient coating inspection tools available to inspect the blasting &coating operations? TOTAL FOR COATING INSPECTION Is there a clerk in the Unit?
4 4 4 4 4 24 3 4 4 4 4 4 4 4
SAEP-316 SAEP-316
20
3 4 4 4 4 4 4
Is there a procedure to set guidelines for record keeping, retention, indexing etc? Are Equipment Files updated/complete? Are Aramco report format used always (NDT, HT, etc.)? Do you have a system for back-up of Inspection records? Do you have an up-to-date master list of all equipment? Do you use computerized inspection data management system to store inspection history? Are all Deviation requests and discretionary letter available?
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4
Max Score
Reference Standard
Are critical records properly protected (e.g. fireproof cabinet) or electronically backed up? Do you have all reference material in the Unit if not available through the Intranet? TOTAL FOR FILING/RECORDS Is the civil inspection performed by a qualified civil inspector? Do you inspect your pipe rack structure/foundation? Is there a qualified refractory / insulation inspector available? Do you have a Database for all the concrete structures and fireproofing in your plants (both onshore and offshore)? Do you grade the concrete deterioration and failure as per the classification described in Aramco standard? Do you use the checklists for concrete pre-pour inspection, during pouring etc? Do you follow up with the laboratory results of the concrete compressibility tests and keep records in the file? Are sufficient civil inspection tools available? Does the unit have a back up inspector for inspection units that has only one inspector? Is the civil inspection required by SAEP-20 being performed timely (no overdue)?
4 4 39 4 4 2 3 4 4 4 4 4 4
00-SAIP-78 00-SAIP-78
39
4 4 2
Job Description
SAEP-20 Para 5.5.8
AJTS/Job Description
Civil Inspection
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4
Max Score
Reference Standard
Do you make sure that the concrete supplier is approved by the Vendor inspection unit, Dhahran and report to them any standard violations in the concrete plant & transport truck? Is the unit informed of all civil activities (daily/weekly schedule) TOTAL FOR CIVIL INSPECTION Is the electrical inspection performed by qualified inspectors?
SAEP-112
4 45 4 4 4 4 4 4 20 4 4 4
42
4
AJTS/Job Description
Electrical Inspection
Does the unit have a back up inspector for inspection units that has only one inspector? Is the electrical inspection required by SAEP-20 being performed timely (no overdue)? Does the electrical inspector have tools and technical resources? Is the unit informed of all electrical activities (daily/weekly schedule) Do you verify that cable splicing is done by certified cable splicers? TOTAL FOR ELECTRICAL INSPECTION
20
4
Non-Destructive Testing
Is there a proper NDT personnel performance tracking program for certification validation? Is contractor personnel qualification checked? Does the Unit have enough NDT equipment and material available?
SAEP-1140 para 9.4 & 9.5 AJTS/Job Description SAEP1144/1146 & ASME V
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 2
Max Score
Reference Standard
Do you have a documented program for calibrating NDT instruments? Does the unit have certified level II RTFI? Does the unit have a dark room available? TOTAL FOR NON-DESTRUCTIVE TESTING Is the Inspection Unit involved in the Management of change (MOC) for issues affecting equipment integrity? Does the Unit get involved in the review of all relevant design packages, repair and modifications? Does the Unit get Involved in periodic meeting with operations, maintenance and Engineering (OME) on equipment integrity related issues? Is GI 2.60 being followed for acceptance of Units after T&I? Are temporary piping installation/repairs tracked through open worksheet until removal or replacement with permanent fix? Do you have limits established for all key and critical process variables that affect corrosion and materials degradation, and are they documented in the operating instructions? Does the material specialist or corrosion engineer evaluate the potential corrosion impact of the proposed change? TOTAL FOR MANAGEMENT OF CHANGE
4 4 2 22 4 4
22
4
00-SAIP-72 00-SAIP-72
4 4 4
00-SAIP-72
4 28
00-SAIP-72
24
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
4 4 4 4 4
Max Score
Reference Standard
Does the unit have a computerized system for Tracking Worksheets? Do you reference standards in your WS's? Do you highlight WS that are outstanding more than a year? Is the Work sheet kept open for temporary repair until it is properly reviewed as permanent or permanent repair is done? Are worksheets highlighted monthly to plant manager for critical or long outstanding worksheet review? TOTAL FOR WORKSHEETS REPORTING Do you have a procedure for assuring proper handling and compliance with Technical Alerts? Do you have a system for tracking self assessment recommendations? Is there a system for tracking and follow up on recommendations issued for proper and timely completion such as PZV shop audit recommendations? Are OID Assessments Status reports issued on time to the Inspection Department Do you have any OID Assessment recommendations exceeding the ETC? TOTAL FOR RECOMMENDATIONS IMPLEMENTATION
4 4 4 4 4 20 4 4
20
0
Management of Recommendations
00--SAIP-77 SAEP-308
4 4 20
SAEP-308 SAEP-308
12
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Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
Actual Score
NA NA 4 NA
Max Score
Reference Standard
Is PMI inspection done by the Unit on received material? Is PMI of alloy material verified after fabrication? Is SAES-A-206, 00-SAIP-07 followed for marking, reporting and documentation? Is existing low alloy piping/equipment PMI spot checked during T&Is? TOTAL FOR POSITIVE MATERIAL IDENTIFICATION
4 3 4 4 4
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100%
80%
Document Responsibility: Inspection Department Issue Date: 31 January 2005 Next Planned Update: 1 February 2008
60%
Performance
40%
20% 0%
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00-SAIP-71