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Inspection Procedure

00-SAIP-76 10 June 2009


Worksheet Control and Tracking Program
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards


Table of Contents

1 Scope............................................................. 2
2 Applicable Documents................................... 2
3 Definitions...................................................... 2
4 Responsibilities.............................................. 3
5 Instructions.................................................... 5
6 Reporting....................................................... 6
7 Suggested E-System..................................... 7

Attachment I Worksheet Data Fields.................. 9


Attachment II Flowchart................................... 11
Attachment III Deterioration and
Abnormality Failure Codes................... 14
Attachment IV Example of Report Formats..... 19

Previous Issue: 31 May 2004 Next Planned Update: TBD


Revised paragraphs are indicated in the right margin Page 1 of 21
Primary contact: Kakpovbia, Anthony Eyankwiere on 966-3-8747226

CopyrightSaudi Aramco 2009. All rights reserved.


Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

1 Scope

This SAIP provides guidelines for inspection personnel on their specific involvement in
the initiation, compilation, review, approval and implementation tracking of worksheets
issued by their inspection unit.

2 Applicable Documents

The following reference documents have been used during the compilation of this
procedure. The latest edition should always be used.

Saudi Aramco General Instruction


GI-1000.500 Maintenance Work Order

Saudi Aramco Engineering Procedure


SAEP-325 Inspection of Pressurized Equipment

Saudi Aramco Inspection Procedure


00-SAIP-78 Inspection Records/Filing Procedure

Saudi Aramco Forms


Form 2643-ENG Worksheet
Form 4745 Records Retention Policy

3 Definitions

Deficiency: Non-conformance to an existing Saudi Aramco standard or other Saudi


Aramco reference document; or deterioration of Saudi Aramco infrastructure; or fault
condition characterized by an inability to perform a required function.

Inspector: A Saudi Aramco (or contract employee) qualified, certified and experienced
within an inspector job description discipline of P&E/W, electrical, civil, coatings,
cathodic protection, non-destructive testing (NDT), telecommunications, or lifting
equipment (crane).

Logbook: As per 00-SAIP-78 definition.

Worksheet: A notification that an item(s) is non-conforming to company specified


standards, procedures or other reference or has deteriorated and requires further
evaluation, repair or modification to be suitable for use. Saudi Aramco Form 2643-
ENG is an example of a current paper-based worksheet. Electronic worksheets can also
be utilized if in accordance with the requirements of this SAIP.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

4 Responsibilities

4.1 Inspector

4.1.1 Identifies a deficiency that requires a worksheet to a proponent.

4.1.2 Compiles a draft worksheet using either Saudi Aramco Form 2643-ENG,
a PIU equivalent form, or an electronic equivalent ensuring all required
data fields are completed and any optional data fields specified by the
unit. Refer to Attachment I for examples of suggested data fields.

4.1.3 References applicable standards, attaches to the worksheet any


construction or isometric drawings, sketches, data, OSI drawings, etc.,
that will help clarify the location, type, nature and characteristics of the
deficiency such that the deficiency is accurately identified, described and
traceable in the field.

4.1.4 Discusses with operations foreman the intent to issue a worksheet and
agrees a SAP Priority for each individual line item (if deemed
necessary). If a priority-1 item per GI-1000.500, then an immediate site
visit shall be made by the Inspector, Foreman and any other necessary
discipline if deemed necessary by the Foreman.

4.1.5 Submits the worksheet to a unit supervisor, or field supervisor (if


approval responsibility has been delegated) for review and approval.
Distributes the worksheet to proponent and circulates copies as
appropriate for PIU once the worksheet is approved for issue.

4.1.6 Monitors the work progress and obtains SAP Notification and Job Order
numbers, or any other changing priority status, or reference number
associated with the job from the proponent until worksheet closure. The
inspectors monitoring activities can consist of surveillance, witness,
record or data review, or hold point inspection points as specified in the
inspection and test plan for the individual item.

4.1.7 Verifies worksheet closure in the field and updates the tracking system
adopted by the PIU every time a change in worksheet status occurs.
Commentary Note:

The inspector should discuss with the applicable operations engineer the
intent to issue a worksheet and make him aware of the intended nature of
the recommendation(s) in the worksheet.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

4.2 Field Supervisor

4.2.1 Review the worksheet for legitimacy, accuracy, identification and


traceability.

4.2.2 Approves the worksheet and signs if paper-based or accepts if electronic


system-based.

4.2.3 Immediately informs the unit supervisor of any priority 1 worksheet.

4.2.4 Monitors the worksheet tracking system updates performed by an


inspector at arbitrary periodic intervals to identify and advise
discrepancies to the inspector.

4.2.5 Conduct worksheet reviews with proponents at least once per month.

4.2.6 Compiles monthly worksheet status reports to proponent management


during the 1st working week of each month per local data needs.

4.2.7 Can cancel a worksheet if responsibility is delegated by unit supervisor.

4.3 PIU Supervisor

4.3.1 Monitors the worksheet tracking system updates performed by an


inspector and field supervisor at arbitrary periodic intervals to identify
and advise discrepancies to the inspector and field supervisor.

4.3.2 Reviews all priority 1 worksheets.

4.3.3 Reviews, approves and issues hard-copy or electronic monthly


worksheet status reports to proponent management during the 1st
working week of each month per local PIU data needs.

4.3.4 Conduct worksheet reviews with proponents at least once per quarter.

4.3.5 Compiles and issues year-end hard copy or electronic monthly worksheet
status reports to proponent management within two weeks from the start
of each Gregorian year.

4.3.6 Is the second level role that can cancel a worksheet.

4.3.7 Is the only role that can delete a worksheet from the system (duplicates,
mistakes, etc.).
Commentary Note:

The Proponent Operations Foreman (or other nominated proponent


representative) assigns work priority of 1, 2, 3, 4, or 5 as per SAP priority

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

criteria in GI-1000.50 section 4 and as agreed with inspector.

5 Instructions

5.1 Organizational System

5.1.1 Worksheets) may be hard copy (paper), or electronic provided it is fully


accepted by the records retention policy (Form 4745) of the department
and Saudi Aramco auditing department policies.

5.1.2 Each inspection unit supervisor establishes a tracking system to control


and track worksheets. The flowchart depicting the tracking system
business workflow and responsibilities is shown in Attachment II.

5.1.3 The plant inspection unit, as part of the internal self assessment shall
review the system for compliance to this SAIP. This review shall occur
once per year to ensure that a system is established, meets the
requirements of this SAIP and is being regularly updated.

5.2 Worksheet Issue

5.2.1 The inspector shall complete all mandatory data fields as required by his
PIU as shown in Attachment I. If the discrepancy is a non-conforming
item the reference and relevant paragraph shall be quoted. If the
discrepancy is deterioration or functional abnormality then a preliminary
failure code may be referenced for the item as depicted in Attachment III.

5.2.2 In the event that consensus cannot be reached on the necessity for
issuance of a worksheet between proponent representatives and
inspector, the matter will be highlighted to the immediate supervisory
roles for each of the parties for further direction.

5.2.3 A worksheet can still be issued by the inspection units to record a


discrepancy and the proponent division head must formally respond to
record and archive the reasons for the cancellation of the worksheet.

5.2.4 The inspector proceeds with all his responsibilities as listed under section
4.1.

5.3 Worksheet Tracking

5.3.1 The inspector shall appropriately monitor progress from initiation to


closure of the worksheets as outlined in section 4.1.9 and the progress
shall be reviewed by the inspection field supervisor and unit supervisor
as outlined in sections 4.2.6 and 4.3.1.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

5.3.2 A standardized table of worksheet status disposition shall be utilized as


follows:
a) Awaiting Maintenance Action
b) Draft Notification (worksheet)
c) No SAP Notification Issued
d) No SAP Work Order Issued
e) No Job Request
f) No Engineering Package
g) No Material
h) Shutdown Required
i) Work In Progress
j) Cancelled
k) On Hold
l) Completed
m) No Service Order
n) Awaiting CP Operations Action
o) Awaiting Contractor Action
p) Superceded

5.3.4 The updating interval of worksheet status is an ongoing activity and the
assigned facility inspector should maintain communication with
proponent operations foremen, planners, maintenance foremen, plant
engineers and field location visits to ascertain the progress. It is the
responsibility of the proponent to advise the inspector of any change in
work progress or status in order that the inspector can verify and update
the worksheet system immediately upon his verification.

5.3.5 Only an inspection field supervisor or unit supervisor can change a


worksheet status to cancelled when justified and documented. No
worksheet covering temporary work is allowed to be closed without
proper and documented review by all concerned parties.

5.3.6 Only a unit supervisor can delete a worksheet from the system. This
shall be supported by proper documented review and justification (unless
it's a duplicate worksheet).

6 Reporting

6.1 Reporting may be hard copy (paper based), or electronic such as automated data
extraction from databases and published to pre defined web reports that can

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

automatically be archived at periodic intervals for historical review, or trending.


Attachment IV gives an example of typical formats that can be produced using
either method.

6.2 The inspection unit supervisor shall issue worksheet reports at periodic intervals
suitable for the local proponent and PIU management but not more than at
3-months intervals. Monthly is an appropriate reporting interval for critical and
long outstanding worksheets and also an end of year summary is recommended.

6.3 The format of the report shall be at the discretion of the inspection unit
supervisor and the data needs of the local proponent management. Management
may specify graphical representations of the data.

6.4 The data of all inspection worksheet status reports shall be formatted in a
manner suitable for storage, archival and easy extraction per the records
retention policy of the business line management.

6.5 The individual data fields (if adopted by PIU) that are suggested in attachments I
and III shall be searchable to produce individual unique reports to allow trending
and identification of gaps.

6.6 Worksheet Status Reports shall group the age of open notifications (worksheets)
from date of issue. These groupings can be dependent upon the SAP priority of
a notification as shown in the table below; the actual format is dependent upon
PIU needs. The only worksheets not considered as open are those with a status
of completed or cancelled.

PRIORITY None 1 2 3 4 5 Total


Age < 1 Month
Age >1 < 3 Month
Age >3 < 6 Month
Age >6 < 12 Month
Age >12 < 24 Month
Age 24 Month
Total

7 Suggested E-System

It is suggested that an electronic worksheet control and tracking system be established


with the following features:

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

7.1 Be able to have unique separate data fields as selected from Attachment I to
allow rapid sorting of data.

7.2 For each change event that occurs be capable of:


a) Automatically recording the initiator name and logon.
b) Automatically recording the date and time of change.

7.3 Producing pre-defined reports automatically at fixed intervals without manual


intervention (attachment IV indicates an example).

7.4 Emailing predefined reports or hyperlinks to report automatically to pre-


determined SAP job roles and/or webpage's if deemed necessary by PIU.

7.5 Have a query mechanism to allow data sorting and extraction to MS-Office
excel spreadsheets.

7.6 Fully auditable and can derive a log of every individual user access, date, time,
and duration.

Revision Summary
10 June 2009 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with editorial changes (changed document responsibility and primary contact to Chairman,
Inspection Engineering Standards Committee).

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment I Worksheet Data Fields


Data Field Typical Entry Examples Comments
Issued by: Admin Area/ Department/ Division/Unit
Worksheet No/Year Division/Unit-xxxx/yyyy
P&E/W, Civil, Elect, C.P, Coatings,
Worksheet Discipline Drop down list selection
Crane, NDT, Telecom
Worksheet Issue Date dd-mmm-yyyy Auto-input by system
Date of Inspection dd-mmm-yyyy
Date Entry Name clerk1 Auto-input by system
Data Entry Logon smitnx0a Auto-input by system
Text or auto input logon of person
Data Entry Signature Auto-input by system
making entry
Inspector Name A.N Other Auto-input by system
Inspector Logon smitnx0b Auto-input by system
Text or auto input logon of person
Inspector Signature Auto-input by system
making entry
Immediate Supervisor Name Text Auto-input by system
Immediate Supervisor Logon smitnx0c Auto-input by system
Text or auto input logon of person
Immediate Supervisor Signature Auto-input by system
making entry
Ops Foreman Name Text Auto-input by system
Ops Foreman Logon boultdb Auto-input by system
Text or auto input logon of person
Ops Foreman Signature Auto-input by system
making entry
Auto-input by system -Only
Supt Name Text required for cases where
declines to perform job
Auto-input by system-Only
Supt Logon hfgftehe required for cases where
decline to perform job
Auto-input by system-Only
Text or auto input logon of person
Supt Signature required for cases where
making entry
decline to perform job
Supt Justification to decline Only required for cases where
Text
worksheet decline to perform job
Drop down list linked to Admin
Facility/Unit No 459, H16, etc (per drafting manual)
Area/Dept/Division Selection
Linked to Facility/Unit No drop
Facility/Unit Name Haw-2 GOSP etc (per drafting manual)
down list
Equipment No 459-SR-1000-1A1M
Equipment Name Drain piping from dehydrator
Equipment Sub-System Common Trains, etc .(i.e. Qurayyah)
Location Text

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment I Worksheet Data Fields (continued)


Data Field Typical Entry Examples Comments
Service Hydrocarbon Drop down list
On-Plot/Off-Plot On-Plot toggle selection
Worksheet applicable to Area Text (Well Services, etc) Drop down list
Linked to FARIS/SAIF System
FARIS/SAIF System ID number 32, 33, etc
Description (drop down list)
Linked to FARIS/SAIF System
FARIS/SAIF System Description Sewer system ID (drop down list linked to
System ID)
SAP Notification No text
SAP Job Number text
SAP Job No Issue Date dd-mmm-yyyy
Engineering Job Number text
Worksheet Priority 1, 2, 3, 4, 5 per SAP criteria Drop down list
As listed in section 5.3.4 (drop
Worksheet Status On-Hold, In Progress etc.
down list)
Auto input by system based on
Worksheet Age <1 Month, <3 month, etc
worksheet issue date (see 6.6).
Worksheet For Action By Foreman, XXXXX/XXXX SAP Job Position Title
Worksheet Scope Text
A worksheet can have many
Worksheet Item No 1, 2, 3, etc
Items
Dependent upon selection of
Non-Conformance, Deterioration or
Worksheet Item No Type Item Type a different choice of
Abnormality, Observation or All
drop down list occurs.
Worksheet Item No Discrepancy
Text
Description
Worksheet Item No Reference or
SAEP-308, Int Corr Drop down list
Deterioration Code
Worksheet Item No Ref
paragraph or Deterioration sub- 3.3.3,
code (if applicable)
Worksheet Item No
Text
Recommendation
Worksheet Closure Date dd-mmm-yyyy Auto input by system
Worksheet Closed by Name 1 Text Auto input by system
Worksheet Closed by Logon fgfbfhr Auto input by system
Worksheet Cancel/Closed by Text or auto input logon of person
Auto input by system
Name making entry
Worksheet Cancel/Closure Text or auto input logon of person
Auto input by system
verified by Name making entry
Worksheet Cancel/ Closure
yrhejs Auto input by system
verified by logon
Worksheet Cancel/Closure by
Text Auto input by system
Name

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment II Flowchart

Identify
Discrepancy NO END
(Inspector)

YES NO

Compile Draft
Discuss with Discuss with
Worksheet Cancel/
Ops Foreman Engineering
Notification Delete?
(Inspector) (Inspector)
(Inspector) (Immediate
Supervisor)

NO

Proponent Acceptible?
Reviews Worksheet (Immediate
Notification & will assign Supervisor) Cancel Delete Draft
YES resources to complete ? Worksheet
(Operations Notification
Foreman) YES (Supervisor or
Immediate Superisor)
Distribute
NO Worksheet
SAP NO Notification
Notification Issued (Inspector)
& Informed Inspector?
Supt
(Operations
Signs for work
Foreman)
not be done
(Ops Supt)

YES
END
YES

Update Status
Shutdown with SAP
Item Notification
& Informed Inspector? (Inspector)
(Operations
Foreman) YES

Update Status
NO to S/D item
(Inspector)

SAP
Job Order Issued & Update Status
Informed Inspector? with SAP Job
(Operations Number
Foreman) (Inspector)

YES

2a 2b

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment II Flowchart (continued)

2a 3b

NO

Proponent Performs work & Performs Surveillance,


controls all contractors ensuring Witness, Hold-Point and review
Status
all Saudi Aramco existing points to ensure all Saudi
Change?
requirements are complied with Aramco existing requirements
(Inspection)
in full are complied with in full.
(Operations Foreman) (Inspector)

YES

YES

Has Updates Status to


advised reflect current
Inspector about 2b
Status
work activities & status (Inspector)
changes?
(Operations
Foreman)
NO

NO

Proponent Performs rework & E-System Auto Notifies


controls all contractors ensuring Immediate Inspection Supervisor
all Saudi Aramco existing of Status Change or if paper
requirements are complied with system Inspector performs
in full notification
(Operations Foreman) (System/Inspector)

Status Review Status


Change Acceptible? Changes
(Immediate Inspection (Immediate Inspection
Supervisor Supervisor)

YES

System Auto-Reminder
First Week
or Supervisor first of
of Calendar Month?
END NO Month
(Immediate Inspection
(System/ Inspection Unit
Supervisor
Supervisor)

YES

3a

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment II Flowchart (continued)

3a

Generate PIU agreed pre-


E-system? formatted status reports first
(Immediate Inspection NO week of every month.
Supervisor (Immediate Inspection
Supervisor)

YES

System generates pre-formatted


Review, correct and issue status
reports automatically and emails
report to pre-defined job
hyperlink to pre-defined job
positions during first week of
positions every month and
every month
archives automatically
(Unit Inspection Supervisor)
(System)

Receivers receive Status End of Year


End of Year
Reports, review and assign any Status?
Status? NO NO
necessary actions (Unit Inspection
(System)
(All participants) Supervisor

YES YES

System generates pre-formatted Generate PIU agreed pre-


annual reports automatically and 3b
formatted annual status reports
emails hyperlink to pre-defined to pre-defined job positions at
job positions at start of each start of each Gregorian year and
Gregorian year and archives archives accordingly
automatically (Unit Inspection Supervisor)
(System)

END

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment III Deterioration and Abnormality Failure Codes


Damage SAP Meridium
Item Damage Code Description Comments
Code Equivalent Equivalent
1 A0001 Abnormal- instrument reading (AIR)
2 A0002 Annulus- pressure build up (APU)
3 B0001 Bent/Kinked
4 B0002 Blown (Fuse)
5 B0003 Breakdown (BRD)
6 B0004 Brittle Fracture API 581
7 B0005 Brittleness due to High Temp Ageing API 581
8 B0006 Broken
9 B0007 Burnt
10 B0008 Burst
11 CP001 C.P - Abnormal Measurement
12 CP002 C.P - Broken CAD Weld / Wire
13 CP003 C.P - Consumed Anodes
14 CP004 C.P - Insufficient Protection
15 CP005 C.P - Interference
16 CP006 C.P - Other
17 C0001 Carburization API 581
18 C0002 Cavitation API 581
19 C0003 Chipped
20 CT001 Coating - Failure D-610 General ASTM-D-610
21 CT002 Coating - Failure D-610 Hybrid ASTM-D-610
22 CT003 Coating - Failure D-610 Pinpoint ASTM-D-610
23 CT004 Coating - Failure D-610 Spot ASTM-D-610
24 C0004 Collapsed
New, no cracks or defects
25 CN000 Concrete Category 0 detectable.

Fine shrinkage cracks present,


minor surface defects may be
26 CN001 Concrete Category 1 present, no evidence of
reinforcing steel corrosion.

Shrinkage cracks present,


surface defects such as
weathering and small accidental
27 CN002 Concrete Category 2 gouges or breakouts, may be
present, small cracks attributed to
reinforcement corrosion may be
present.

Severe surface damage due to


weathering or chemical attack,
open cracks due to reinforcement
28 CN003 Concrete Category 3 corrosion. Hollow sounding areas
due to reinforcement corrosion,
spalling.

Severe cracking or breakup due


29 CN004 Concrete Category 4 to reinforcement corrosion.
Reinforcement may be exposed.
30 CN005 Grout Category 5 No cracks or defects present.
Fine shrinkage cracks, no loss of
31 CN006 Grout Category 6 bond with concrete.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment III Deterioration and Abnormality Failure Codes (continued)


Damage SAP Meridium
Item Damage Code Description Comments
Code Equivalent Equivalent
Small cracks, some loss of bond
with concrete, minor surface
32 CN007 Grout Category 7 damage, metallic aggregate in
exposed area.
Break outs, major damage,
33 CN008 Grout Category 8 extensive loss of bond with
concrete.
34 CR001 Corrosion - Ammonia API 581
35 CR002 Corrosion - Atmospheric API 581
36 CR003 Corrosion - Biological API 581
37 CR004 Corrosion - Boiling Water/ Condensate API 581
38 CR005 Corrosion - C02 API 581
39 CR006 Corrosion - Caustic API 581
40 CR007 Corrosion - Chlorine/Sodium Hyperchlorite API 581
41 CR008 Corrosion - Cooling Water API 581
42 CR009 Corrosion - Crevice API 581
43 CR010 Corrosion - Dealloying API 581
44 CR011 Corrosion - Erosion API 581
45 CR012 Corrosion - Flue Gas API 581
46 CR013 Corrosion - Flue Gas Dewpoint API 581
47 CR014 Corrosion - Galvanic API 581
48 CR015 Corrosion - H2/H2S Sulfidation API 581
49 CR016 Corrosion - High Temp Oxidation API 581
50 CR017 Corrosion - Hot Corrosion API 581
51 CR018 Corrosion - Hydrochloric Acid (Hcl) API 581
52 CR019 Corrosion - Hydrofluoric Acid API 581
53 CR020 Corrosion - Injection Point API 581
54 CR021 Corrosion - Inorganic Chlorides API 581
55 CR022 Corrosion - Naphthenic Acid API 581
56 CR023 Corrosion - Organic Chlorides API 581
57 CR024 Corrosion - Organic Sulfur API 581
58 CR025 Corrosion - Phenol API 581
59 CR026 Corrosion - Phosphoric Acid API 581
60 CR027 Corrosion - Soil API 581
61 CR028 Corrosion - Sour Water API 581
62 CR029 Corrosion - under Fireproofing API 581
63 CR030 Corrosion - under Insulation API 581
64 CK001 Cracking - Amine API 581
65 CK002 Cracking - Ammonia API 581
66 CK003 Cracking - Carbonate API 581
67 CK004 Cracking - Caustic API 581
68 CK005 Cracking - Chloride Stress Corrosion API 581
69 CK006 Cracking - Corrosion Fatigue API 581
70 CK007 Cracking - Hydrofluoric Acid API 581
71 CK008 Cracking - Liquid Metal Embritttlement API 581
72 CK009 Cracking - Stress Corrosion API 581
73 CK010 Cracking -Polythionic Acid (PTA) API 581
74 C0005 Creep API 581
75 C0006 Creep & Stress Rupture API 581
76 C0007 Crushed
77 C0008 Cut

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment III Deterioration and Abnormality Failure Codes (continued)


Damage SAP Meridium
Item Damage Code Description Comments
Code Equivalent Equivalent
78 D0001 Decarburization API 581
79 D0002 Delayed- operation (DOP)
80 D0003 Dent/Dented
81 EM001 Embrittlement - 885 F API 581
82 EM002 Embrittlement - Carbide Precipitate API 581
83 EM003 Embrittlement - Reheat Cracking API 581
84 EM004 Embrittlement - Sigma & Chi phase API 581
85 EM005 Embrittlement - Temper API 581
86 ER001 Erosion - Droplets API 581
87 ER002 Erosion - Solids API 581
88 E0001 Erratic- output (ERO)
89 F0001 Failed- to close on demand (FTC)
90 F0002 Failed- to function on demand (FTF)
91 F0003 Failed- to open on demand (FTO)
92 F0004 Failed- to regulate (FTR)
93 F0005 Failed- to start on demand (FTS)
94 F0006 Failed- to stop on demand (STP)
95 F0007 Failed- to synchronise (SYN)
96 F0008 Fasteners - Loose
97 F0009 Fasteners Incorrect
98 F0010 Fatigue- Mechanical
99 F0011 Fatigue -Thermal
100 F0012 Faulty- output frequency (FOF)
101 F0013 Faulty- output voltage (FOV)
102 G0001 Galled
103 G0002 Gasket Type Incorrect
104 H0001 Hardening API 581
105 HYD01 HIC - Cyanide Stress Cracking API 581
106 HYD02 HIC Blisters API 581
107 HYD03 HIC -Cracking / Step Wise Cracking API 581
108 HYD04 HIC SOHIC API 581
109 HYD05 HIC Sulphide Stress Cracking API 581
110 H0002 High- output, unknown reading (HIU)
111 H0003 High- output/reading (HIO)
112 H0004 Holed
113 HYD06 Hydrogen Attack - Embrittlement API 581
114 HYD07 Hydrogen Attack - High Temperature API 581
115 HYD08 Hydrogen Attack - Hydriding API 581
116 I0001 Incipient Melting API 581
117 I0002 Insufficient- heat transfer (IHT)
118 INS01 Insulation - Banding Broken/Missing
119 INS02 Insulation - Bulging
120 INS03 Insulation - Damage Penetrations
121 INS04 Insulation - Missing Jacketing / insulation
122 INS05 Insulation - Sealing Deterioration
123 I0003 Internal Fittings loose/broken
124 I0004 Internal Fittings Tray loose
125 I0005 Internal Foreign Deposits
126 LK001 leakage- External/ fuel (ELF)
127 LK002 leakage- External/ process medium (ELP)

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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment III Deterioration and Abnormality Failure Codes (continued)


Damage SAP Meridium
Item Damage Code Description Comments
Code Equivalent Equivalent
128 LK003 leakage- External/ utility medium (ELU)
129 LK004 Leakage- in closed position (LCP)
130 LK005 leakage- Internal (INL)
131 LK006 Leaks - Existing Temporary Clamps
132 LK007 Leaks - Other
133 LK008 Leaks - Process
134 LK009 Leaks - Steam Tracing
135 L0001 Low- output (LOO)
136 L0002 Low- output, unknown reading (LOU)
137 L0003 Low-Very low output (VLO)
138 M0001 Material - Incorrect
139 M0002 Melted
140 M0003 Metal Dusting API 581
141 MA001 Misaligment -Other
142 MA002 Misaligment - Restricted Movement
143 MA003 Misalignment - Expansion Joint
144 N0001 Nitriding API 581
145 N0002 No- demand (OWD)
146 N0003 No- output (NOO)
147 N0004 Noise (NOI)
148 OTH01 Other (OTH)
149 OTH02 Overheating (OHE)
150 OTH03 Overload (Plastic Collapse) API 581
151 P0001 Parameter deviation (PDE)
152 P0002 Pierced
153 P0003 Plugged/Choked (PLU)
154 P0004 Punctured
155 R0001 Ruptered
156 S0001 Sand Encroachment (External)
157 S0002 Scaled / Scaling
158 S0003 Scratched / Scored
159 S0004 Seized
160 S0005 Service- Minor problems (SER)
161 S0006 Shattered
162 S0007 Sliding Wear API 581
163 S0008 Softening due to Overaging API 581
164 S0009 Spheroidization & Graphitization API 581
165 S0010 Splintered
166 S0011 Split
167 S0012 Spurious- high level alarm signal (SHH)
168 S0013 Spurious- low level alarm signal (SLL)
169 S0014 Spurious- operation (SPO)
170 S0015 Spurious- stop (SPS)
171 S0016 Strain Ageing API 581
172 S0017 Structural- deficiency (STD)
173 S0018 Subsidence
174 SUP01 Supports - Bottomed Out Springs
175 SUP02 Supports - Brace Distortion/ Leakage
176 SUP03 Supports - Counter Balance Condition
177 SUP04 Supports - Hanger Distortion or Breakage

Page 17 of 21
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment III Deterioration and Abnormality Failure Codes (continued)


Damage SAP Meridium
Item Damage Code Description Comments
Code Equivalent Equivalent
178 SUP05 Supports - Loose Brackets
179 SUP06 Supports - Shoes off Supports
180 SUP07 Supports - Slide Plates/ Rollers
181 T0001 Thermal Racheting API 581
182 T0002 Torn
183 T0003 Twisted
184 UNK01 Unknown
185 VIB01 Vibration - Excessive Overhung Weight
186 VIB02 Vibration - Inadequate Support
187 VIB03 Vibration - Loose Supports
188 VIB04 Vibration - Thin, small bore piping
189 VIB05 Vibration - Threaded Connections
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227

Page 18 of 21
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment IV Example of Report Formats

xxxxxxx Inspection Unit Worksheets Summary

Print Date Tuesday ~ 27 January, 2004

WS# WS Date Maint. W.O. Equipment Priority Status


08xx/2003 xx/xx/2003 101xxxx 1 1/2" DRAIN LINES 4 Await Maint. Action
0xxx/2003 xx/xx/2003 1018xxx 4" JETTING LINES 4 Await Maint. Action
08xx/2003 1x/xx/2003 101xxx55 4" WASH WATER LINE 4 Await Maint. Action
08xx/2003 1x/xx/2003 1018xxx 4" JETTING WATER LINES 4 Await Maint. Action
08xx/2003 1x/xx/2003 xxxxx SAFETY RELIEF VALVES 3 Work In progress
08xx/2003 1x/xx/2003 1018xxxx 12" DIA. WATER LINE 4 Await Maint. Action
08xx/2003 0xxx/2003 1018xxxx SMALL DIAMETER PIPING 4 Shutdown Required
08xx/2003 0xxx/2003 1018xxxx FIRE WATER MONITORS 2 Work In progress
08xx/2003 0xxx/2003 1018xxxx 10" GAS LINE FROM LPPT 3 Work In progress
08xx/2003 0xxx/2003 1018xxxx 2"X1500# ELBOWS D/S OF LC 4 Work In progress
08xx/2003 1x/xx/2003 1018xxxx LEVEL COLUMN PIPING 3 Await Maint. Action
08xx/2003 1x/xx/2003 1018xxxx CONDUIT SEALS 3 Await Maint. Action
08xx/2003 2x/xx/2003 1018xxxx 2" & 4" DRAIN LINE 4 Await Maint. Action
08xx/2003 2x/xx/2003 1018xxxx 2" CHARGE PUMPS DRAIN 4 Work In progress
08xx/2003 2x/xx/2003 1018xxxx CHEMICAL CONCRETE 5 Work In progress
Number of Worksheets on this Plant: 15

Page 19 of 21
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment IV Example of Report Formats (continued)

xxxxxx AREA CORROSION CONTROL/INSPECTION xxxxx


xxxxxxxx INSPECTION UNIT (xxxx)
xxxxx PRODUCING DIVISION
January 28, 2004

Worksheet Summary Chart

120

100

80

60

40

20

0
Pre Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
2004

Opened Closed Shutdown W/S For Action Outstanding

Pre
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
2004
Opened 9 7
Closed 10 11
Shutdown 7 9
W/S For Action 99 95
Outstanding 106 104

Notes:
Opened = Worksheets opened between the 1st and last day of the month.
Closed = Worksheets completed and cancelled during the above period.
S/D Required = Cumulative number of "Shutdown Required" worksheets at the end of the month.
W/S for Action = Cumulative worksheets except "Completed, Cancelled and S/D Required ".
Outstanding = Total worksheets (cumulative) except "Completed" and "Cancelled" at the end of the month.

Page 20 of 21
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-76
Issue Date: 10 June 2009
Next Planned Update: TBD Worksheet Control and Tracking Program

Attachment IV Example of Report Formats (continued)

xxxxxxx CORROSION CONTROL\ INSPECTION xxxxxx


xxxxxx INSPECTION UNIT
xxxxx Producing
Wednesday, January 28, 2004
Worksheet Priority & Status Chart

32

28

24
<= 6 months
> 6 month <= 1 year
> 1 year
20

16

12

0
2

n
io

tio
&

ct

Ac
4

A
3,

gr

.
ps
En

Priorities 2 3,4 & 5 Engr Ops. Total


Action Action
<= 6 months 1 16 4 12 33
Time > 6 month <= 1 year 0 29 3 6 38
Worksheets > 1 year 0 28 0 5 33
Total 1 73 7 23 104
Are
Outstanding

Priority "1" - Emergency Work: To be done immediately (Safety, Production Loss or Equip Damage)

Priority "2" - Urgent Work: Start within 48 hours and complete as soon as possible.
Priority "3,4 & 5" - Normal Work: May schedule beyond 48 hours as maintenace resources permit.

Engr Action - Worksheets issued for engineering evaluation or for a package.


Ops Action - No work order/No Job request/or SD required issued by Operations.

Page 21 of 21