NEW 1 of 56: Saudi Aramco Oil Company (Saudi Aramco) Yanbu Refinery Instruction Manual

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)
YANBU REFINERY INSTRUCTION MANUAL
YRIM No.: 1156.00

Revision No.: 00
Issue Date
SUBJECT: YRD Inspection Program

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Engineering Inspection Unit
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Saudi Aramco Loss Prevention Policy

Saudi Aramco will conduct its business in a manner which prevents incidents or accidents which cause
loss of life, bodily injury or illness, or damage to property, assets or the environment. As reflected in
Saudi Aramcos Corporate Values, the Company will continuously maintain the highest standards of
safety, security, health and environmental protection. Accordingly, the Company will:
Advise all employees and contractors of their loss prevention responsibilities and regularly
measure their performance;
Evaluate, identify and eliminate or manage safety risks prior to beginning any operation or activity
and continue to review such risks, complying with all applicable laws and regulations;
Communicate loss prevention objectives and procedures regularly to employees and all affected
parties;
Train employees and provide resources to maintain job competencies, including loss prevention
responsibility and accountability;
Design and construct Company facilities utilizing recognized best technology and practices to
safeguard property and people;
Operate and maintain Company facilities to assure safe operations;
Require that contractors, suppliers and others adhere to the Companys loss prevention policies,
procedures and goals;
Prepare for emergencies and other contingencies and respond promptly and effectively to any
incidents or accidents resulting from operations;
Report all incidents, review performance and communicate progress;
Promote off-the-job safety and community awareness, and
Review and improve the Companys loss prevention program and performance continuously.
Saudi Aramco:
[ X ] New Instruction
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Purpose & Objective
The objective of this process is to ensure compliance with all established company
inspection procedures/programs and maintain required level of asset integrity throughout
Yanbu Refinery facilities.
2. Owner or Champion: YRD Engineering Inspection unit is the owner of these

programs.
3.
Applicability
This comprehensive inspection document contains several inspection procedures/programs

which are applicable to YRD facilities.
4. Corporate Expectations: YRD follows all the guidelines as outlined in SMS Manual
Refer to YRD SMS website.
5.
Process Description
The main objective of this comprehensive inspection programs is to enable YRD inspection
team to comply with all corporate requirement for assets integrity and to highlight
deficiencies observed that require repair or action necessary to prevent further damage to
the equipment. Also this document specifies the responsibilities of all YRD personnel
pertaining to assets integrity. The area inspector shall use this document as a supplement to
the plant inspection index (00-SAIP-71). This document includes a section for each
inspection procedure/program which will include a brief description of the
procedure/program, a list of the related standards and engineering/inspection procedures, a
table which specifies the responsibilities and the required documentations and where it will
be filed.
6.
Responsibilities
a) YRD Inspection Unit Supervisor owns the overall responsibility for implementing the
periodic inspections at Yanbu Refinery facilities
b) YRD Inspection Unit Field Supervisor shall provide qualified inspection personnel to
conduct the inspection activities including tests. The Inspector will examine the system
during the inspection/test and issue a necessary test report per established
procedures after successful completion of each inspection/test. The inspection results
shall be retained as a record in the Inspection Filing System.
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c) The refinery Operation Foreman is responsible to ensure that all required inspection
programs are conducted in his plant limit as per inspection schedules.
d) The Supervising Operator of each unit shall be responsible to ensure that all proper
work permits have been issued.
e) The Area Maintenance/T&I engineer shall be responsible for providing the necessary
manpower and equipment (crane, man lift, scaffolding, etc) to perform the required
inspection activities and to rectify deficiencies.
f) The Area Process Engineer shall be responsible for preparing and distributing the
required procedures (hydrotest procedures, leak test, shutdown, start up etc) as
required to assist in conducting the inspection activities in accordance with relevant
company standard, or YRD internal procedures.
g) The detail responsibilities of all inspection programs are listed under in each program
7.
Training & Competency
YRD Engineering Inspection Unit shall provide required functional training to meet the
competencies required for conducting inspection activities per company established guidelines
and programs. YRD Inspection Unit is following the corporate training requirements to certify YRD
inspectors and all required courses and exams shall be fulfilled prior to certifying the inspectors.
8.
Documentation
The Engineering Inspection Unit shall complete, issue and distribute the inspection reports
including test information sheets per relevant Saudi Aramco inspection procedures to the
area Operations Foreman and area OME team. Records of all tests shall be maintained by
YRD Inspection Unit as will be detailed in the documents for each inspection
procedures/programs.
9.
References
All relevant references are indicated under each Procedure/Program in this document.
YRD SMS: Inspection Programs

NEW
Saudi Aramco:
ELEMENT 5 ASSET INTEGRITY
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YRD List of Inspection Programs:
1- Relief valve installation, inspection and testing:

Refer to SMS # 5. (YRD E5 07) for more details.
2- Internal Inspection of Equipments (T&I) :
Procedure/Program Description
Internal inspection of all static equipments such as columns, vessels, drums, storage tanks,
heat exchangers, reboilers and boilers are conducted by visually inspecting them and by
using Non-Destructive Testing methods such as Magnetic Particle Testing, Dye Penetration
Testing and Radiography Testing for all internal welds, heat affected zone and base metals,
all attachment welds and nozzles. The internal inspection should also cover the internal
coating, refractory material and the mechanical integrity of the internal elements such as
trays and packing. In the other hand, the chemical material inside the vessels (Desiccant,
Sieve, catalyst, etc) should be inspected by the area process engineer and area operation
supervisor.
The final box up of static equipment in YRD is carried out as per the applicable SAESs and
SAEPs. The project inspector will perform the internal inspection for the static equipments
which are built by PMT along with YRD inspector. During T&I and up on request, YRD
inspector will perform the internal inspection of static equipments prior to signing the final
closure certificate. Deficiencies shall be reported to PMT/ YRD Maintenance to rectify prior to
signing the final closure certificate.
Referenced Standards/Procedures
SAEP-306 Assessment
SAEP-317 Testing & Inspection of Shell & Tube Exchangers
SAEP-325 Inspection
SAEP-1141
Industrial Radiation Safety
SAEP-1143
Radiographic Examination
SAEP-1144
Magnetic particle examination of welds and components
SAEP-1145
Liquid penetrant examination of weld and components
Saudi Aramco:
of the remaining strength of corroded pipes
requirements for pressurized equipment
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SAEP-1146
SAEP-343 Risk Based Inspection (RBI) for In-Plant Static Equipment and piping.
00-SAIP-80
Guidelines for Process Equipment Inspection
32-SAIP-11
Inspection of Air cooled Exchangers
01-SAIP-02
Retirement thickness of In-plant Piping
SAES-C-001
SAES-D-001
Process Design of Trays and Packing

Design Criteria for Pressure Vessels
SAES-D-109
Design of Small Tanks
SAES-E-004
Design Criteria of Shell and Tube Heat Exchangers
SAES-E-007
Design Criteria of Air-Cooled Heat Exchangers
SAES-F-007
System Design Criteria of Flares
SAES-H-001
Selection Requirements for Industrial Coatings
SAES-N-110
Installation Requirements Castable Refractories
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API 510
Replaces
Manual Ultrasonic thickness testing
Pressure Vessel Inspection Code
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Responsibilities:
Activities
Assigned to
Inspection
PMT/PID
Activities during
construction
period
Remark
Project inspector shall perform the following activities:
Inspects the static equipment during receiving and storing in

the yard.
Inspects the static equipment during installation.

Inspects the alignment of static equipment.
Inspects the static equipment for internal installation.
Inspects and witness the hydrotest and lay up of static

equipment if required.
PMT
PMT/PID/PROPONENT inspects the static equipment for final boxPID inspector up and signs the final box-up certification.
YRD inspector
Inspection
Activities(during
T&I and up on
request)
Area
inspector
Include performing the required NDT test and witnessing

hydrotest and leak test. Additional inspectors will be assigned as
needed to assist the area inspector during T&I
Maintenance
Activates
T&I engineer
Include providing the necessary manpower and equipment (crane,

man lift, scaffolding, etc) to perform the required T&I activities
Work Permit
Area
operation
supervisor
Include providing the necessary work permit and initiating

deviation letter to postpone the T&I.
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Procedures
(hydrotest, leak
test, shutdown,
start-up etc)
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Area process Prepare and distribute the required procedures if required

engineer
to assist in conducting the T&I in accordance with relevant
company standard, or YRD internal procedures
Inspect chemical Area process Inspect the internal chemical material (Desiccant, Sieve,
material
engineer /
Catalyst, etc) and provide the required specification if
Operation
replacement is needed.
supervisor
Documentations:
1. Approved SIS, Drawings, P&ID, SAIC and final box up certification
2. Pre-T&I Report Issued by the area inspector
3. Inspection Recommendations Issued by the area inspector
4. Post T&I Report Issued by the area inspector
5. Deviation Letter to postpone the scheduled T&I initiated by operation.
The area inspector shall document the above documentations in:
1. Equipment file
2. Equipment file in the shared folder
3. Update the SAIF program if required
3- External mechanical Inspection of Equipment, piping and components:
Procedure/Program Description:
External visual inspection of all mechanical equipments, piping and their components are
carried out as per the Inspection Schedule established as per the guidelines indicated in
SAEP-20 which specifies 24 months interval for onshore areas.
00-SAIP-75
Saudi Aramco:
External Visual Inspection Procedure
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SAEP-20 Equipment Inspection Schedule
Responsibilities:
Activities
Assigned
to
Remark
Inspection Inspection
Activities Unit
Supervisor
Area
inspector
Assigns inspector(s) to carry out external inspection of all YRD

facilities.
Ensure inspection worksheet(s) are issued to rectify deficiencies
reported in
the external inspection.
Ensure that all equipment within his area of responsibility is listed in the EIS
specifying inspection intervals as required by SAEP-20. A schedule of
twoyear external inspections shall be made available and is updated
regularly.
Perform two-year external inspection of all existing equipment within his
area listed in the approved EIS with the corresponding checklist(s);
per
attachments of 00-SAIP-75. Complete individual checklist for
pressure
equipment per SAEP-20, paragraph 5.5.8. Use the 00-SAIP-75 checklists
as
references only when inspecting piping if not individually listed in the
EIS.
Inspection of civil structure will be inspected (every two-year) by
the
assigned civil inspector while electrical equipment will be
inspected
(annually) by the assigned electrical inspector.
Prepare a detailed on-stream inspection report of the present condition
of
the equipment highlighting the deficiencies observed that require
repair or
action necessary to prevent further damage to the equipment and
issue
IWS or LBE if required.
Request engineering evaluation if deemed necessary.
Maintenan Maintena
Saudi Aramco:
Update the SAIF program
Include providing the necessary manpower and equipment (crane, man
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lift,
scaffolding, etc) to perform the required inspection activities and rectify
the
highlighted deficiencies.
Activates
nce
Engineer
Work
Permit
Include providing the necessary work permit and initiating deviation letter
Area
to
operation postpone the T&I.
supervisor
Documentations:
1. Completed external check list survey
2. Inspection Worksheet highlighting the Inspection Recommendations
The area inspector shall document the above documentations in Equipment file and
Inspection unit shared folder
4- Inspection of Spring Support:
Inspection requirement for spring supports for pipes and equipment during routine visual external
inspection. Inspections of spring support are required as per 00-SAIP-75. Inspection is required
to examine all items related to Spring support such as I beam support, beam attachment pin,
hanger attachment, integrity of clamps, eye-bolts & hanger rod, spring coil & housing, Hot/cold
load positions marked on tap plate, spring coil fully compressed, coating & galvanizing, safety
hooks availability, davits & lifting lugs in good condition and spring identification. Test results are
reviewed and any defect found shall be sent to Area operation foreman to rectify.
00-SAIP-75
Visual external inspection procedure
Responsibilities:
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Remark
Inspection
Projects Inspector
Activities during
construction
period
Assure that all spring supports for new project are working
Inspection
Activities
Include the following:
Area inspector
Carry visual external inspection on spring support every

two years.
Make sure all spring mechanism are working, all parts
are free of corrosion and free of any deficiency
Issue recommendation for replacement as needed
Work Permit
Area operation
supervisor
Include providing the necessary work permit and inform

Maintenance to start maintenance activities.
Maintenance
Activates
Maintenance
Technician
Include providing the necessary manpower and equipment

(crane, man lift, scaffolding, etc) to perform the required
inspection activities and rectify the highlighted deficiencies.
Documentations:
1. Equipment file
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5- Inspection Of thermowell:
Inspection is carried out on all thermowell that can be dismantled during plant T&I. Inspection
of all thermowells is conducted as per standard drawing AB-036019 and inspection results
are reviewed and any defect found shall be sent to Area operation foreman to rectify. All
results are recorded and filed along with the post-T&I reports.
SAES-J-400
Temperature
SA-8020-418 Instrument Specification Sheet - Thermowell
AB-036019
CSD Technical Alert 05 issued on 5/17/1993
Thermowell Assembly and detailed
Responsibilities:
Activities
Inspection
Activities
during
construction
period
Saudi Aramco:
Assigned to
PMT & new
project design
reviewer
Remark
Assure that all thermowells are made of 316 SS. Other materials
shall be approved by CSD.
Assure the proper length of thermowell is installed.
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Area inspector Include the following:
Inspect all thermowells in vibrating services. Thermowells

longer than 7.5 inches required more attention
Perform visual inspection thermowells for cracks scratch

Perform UT reading & PT on the thermowell during T&I
Issue recommendation for replacement if required.
Work Permit Area operation Include providing the necessary work permit
supervisor
maintenance to start maintenance activities.
Maintenance Maintenance
Activates
Technician
and
inform
Remove and re-install the thermowells which shall be marked prior

to removal. Make sure they are return to the same locations.
Documentations:
List of all thermowells inspected during each T&I. The area inspector shall file this documentation in:
1. Equipment file
6- Hydrostatic Testing for repaired
components Procedure/Program
Description:
Hydrostatic testing of equipment and piping is conducted after completing major repair,
renovation or alternation and replacement in kind of equipment and piping as per the
guideline given the following standards / procedures.
SAES-A-004
General Requirements for Pressure Testing
SAES-L-150
Pressure Testing of Plant Piping and Pipelines
00-SAIP-06
Pressure Test Requirements
GI-0002.102
Pressure Testing Safely
ASME B31.1
Saudi Aramco:
Power Piping
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ASME B31.3 Process Piping
ASME SEC VIII D1 & 2 Boilers and Pressure Vessel Code
NB 23
National Board of Inspection Code
Responsibilities:
Assigned
Activities
to
Inspection
Activities
Area
inspector
Remark
Request and witness pressure testing for all equipments/lines which
undergo a repair or alteration that affect the equipments/lines
integrity. The test shall be as per SAES-L-150 and in accordance with
the fabrication code. As a guideline for boiler hydrotest during T&I or
repair work, request and witness pressure test as per boiler data
sheet. For major repair, the pressure test shall be 1.3 X-DP. If no
repair was done, the test shall be up to the DP. This test is required to
check tube integrity. For shell and tube heat exchanger, request and
witness hydrotest for the shell and another hydrotest for the tube
after each T&I and before the exchanger is turn to operation.
The
tests shall be as per equipment data sheet and fabrication code.
Test media shall be approved by standards. Pneumatic test may be
subtitled if water cant be used provided that an approval from
inspection department and loss prevention is granted.
A hydrotest report shall be issued and filed in the equipment file for
each pressure test.
Area
Procedures process
(hydrotest, engineer
shutdown,
start-up
etc)
Work
Permit
Saudi Aramco:
Area
Prepare and distribute the hydrotest procedures to assist in

conducting the hydrotest in accordance with relevant company
standard, or YRD internal procedures
Include providing the necessary work permit and inform maintenance to
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operation
supervisor
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start maintenance activities.
Maintenanc Maintenanc Provide the necessary manpower and equipment to perform

e
e
the
Activates
engineer
required hydrotest. The maintenance crew shall be aware of GI
requirement and well trained to perform the hydrotest.
Documentations:
Pressure test report for each pressure test which shall be filed in the:
1. Equipment file
7- Planning and Scheduling of Equipment Inspections in the plant:
Inspection planning and scheduling of all equipment and piping in the plant is carried out as
per the guidelines indicated in SAEP-20. An Equipment Inspection Schedule should be
prepared for each group of equipments such as columns, drums, heat exchangers, boilers
and storage tanks indicating the initial T&I and subsequent T&I intervals. Based on the T&I
findings, the period for the next T&I will be determined by YRD inspection unit and the EIS
will be updated if required. YRD Inspection unit will initiate any revision to the approved EIS
and route it for approval. As required by SAEP-20, the revised EIS shall be approved by:
1. YRD Inspection Unit supervisor
2. YRD Engineering Superintendent
3. YRD Operation Superintendent
4. ID manager
5. YRD manager
SAEP-20
Equipment Inspection Schedule
SAEP-309
Responsibilities:
Activities
Saudi Aramco:
Inspection of Community and Operations Support Facilities

Assigned to
Remark
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Prepare Original
EIS
PMT / Inspection PMT shall prepare and route for approval the EIS for
Unit supervisor
Equipment built by PMT. Inspection Unit supervisor shall
prepare and route for approval the EIS For equipment built
by YRD maintenance.
Maintaining the
EIS
Area inspector
Include filling the approved EIS, initiating any revision to the

approved EIS and updating the SAIF program.
Documentations:
The Approved EIS shall be filed by the area inspector in:
1. Equipment file located in the Inspection filling room
Small Nipple inspection program:

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The small bore piping nipple inspection is intended to monitor the condition of in service
piping nipple of size 1 inches and smaller. Internal / external corrosion and welding defects
will be monitored. Each piping system will be categorized as per the corrosion severity and
classified as per the potential consequence on leaks. Based on corrosion category and piping
class, the inspection frequency will be fixed.
The piping inspection frequency is determined from the Nipple Inspection Intervals Matrix
provided in 01-SAIP-01. The subsequent nipple inspection will be adjusted based on the
inspection findings. Inspection frequency for injection points shall not exceed three years as
stipulated in 01-SAIP-02.
Radiography testing (RT) will be the primary inspection method for the internal or external
corrosion of the nipple, for all services including cryogenic service. If welding defects were found
during the inspection, the acceptance criteria provided in 01-SAIP-01 shall be utilized. Ultrasonic
Thickness (UT) inspection shall be utilized when RT is not conclusive. In addition to radiography,
MT or PT should be used to inspect for cracks in vibrating services or austenitic stainless steel
welds. Visual inspection should be performed on all pipe nipple systems to determine the need
for replacement or repairs due to external corrosion, threads not covered by seal weld, vibration
fatigue or possibility of overloading of the nipple.
The nipple shall be replaced when the retirement thickness is reached. The retirement thickness
shall be the lower of the minimum thickness by code and the structural minimum thickness. If the
retirement thickness has not been reached but there is metal loss, the remaining life shall be
calculated. The nipple shall be replaced if the remaining life is less than either the next inspection
interval or the next T&I. If the piping system cannot be shut down for nipple replacement, temporary
repair shall be considered until replacement in the next schedule T&I.
The nipple shall be replaced when the retirement thickness is reached. The retirement thickness
shall be the lower of the minimum thickness by code and the structural minimum thickness. If the
retirement thickness has not been reached but there is metal loss, the remaining life shall be
calculated. The nipple shall be replaced if the remaining life is less than either the next inspection
interval or the next T&I. If the piping system cannot be shut down for nipple replacement, temporary
repair shall be considered until replacement in the next schedule T&I.
All pipe nipples that have been identified as having incorrect metallurgy for the piping system
should be removed and replaced regardless of the remaining wall thickness. All alloy
replacement nipples, valves and welds should be evaluated using an approved Positive
Material Identification (PMI) instrument before installation.
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Nipples which are not braced and subjected to vibration should be adequately braced per
SAES-L-310, paragraph 20.2.3 and Saudi Aramco Standard Drawing AB-036521 to prevent
future fatigue failure.
01-SAIP-01 Small Nipple Inspection Program
SAES-L-310 Design of Plant Piping
AB-036521 Bridge Weld and Typical Brace Seal Welded and Socket Welded Valves on
Process Lines
Responsibilities:
Activities
Assigned to
Remark
Inspection Activities
OSI Coordinator
Add Piping System to SAIF for nipple

Inspection
Corrosion Engineer and Determine Inspection Frequency

OSI coordinator
Area inspector
Schedule piping for inspection
NDT Technician
Conduct required Inspection
Work Permit
Area
supervisor
operation Include providing the necessary work

permit and inform maintenance to start
maintenance activities.
Maintenance Activates
Maintenance engineer Include providing the

necessary
manpower and equipment (crane, man
lift, scaffolding, etc) to perform the
required inspection activities and rectify
the highlighted deficiencies.
Documentations:
1. Piping Isometric
2. NDT Report
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3. Nipple shall be added as additional OSI point

4. Update the SAIF program
The above documents (1 &2) shall be filed in the inspection unit filling room.
9- On-Stream inspection of equipment and piping:
Systematic monitoring program of piping, vessels and tanks for general loss of wall
thickness and localized metal loss in critical processes is established and carried out
as per the guidelines given in SAEP-1135 with the utilization of SAIF inspection
program.
SAEP-1135
SAIF
On-Stream Inspection Administration

System Assurance & Inspection of FacilitiesOSI Module
Responsibilities (as per SAEP-1135)

Activitie
Assigned
s
to
Remarks
During
PMT
Saudi Aramco:
Project Management Team (PMT) or construction contractor shall:
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constructi
on
Assign TML locations as detailed in Appendix B of SAEP-1135 and conduct

baseline
survey to obtain original wall thickness of new equipment and piping as
required in
SAEP-122.
Inspection YRD
Assure the availability of an active OSI program and all unit personnel
have an
Activitie
s
Inspectio
n
Unit
Supervis
or
Corrosio
n
Engineer
and Area
Saudi Aramco:
access to the program for the required action.

Assure the availability of training program to maintain effective
administration of
the OSI Program.
Issue a quarterly OSI Progress Report to the plant management and
the annual
equipment condition reports to the plant maintenance and operation
superintendents.
Corrosion Engineer with assistance from the Process Engineer shall be
responsible for
the following:
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OSI
Coordinator
Inspection
Field
Supervisor
Planning and running of the OSI Program.

Issue the required OSI progress reports
and OSI TML overdue reports to the unit
supervisor.
Coordinate for NDT actions between the area

inspectors and the NDT technicians.
Issue report with for circuits where

corrosion rates greater than 5 mpy or
equipment with remaining life less than
twice the OSI interval to the Corrosion
Engineer
Assure all plant static equipment is

monitored by OSI program.
Review OSI data with the responsible
area inspector and advise accordingly.
Assure OSI program data is being reviewed,
analyzed, and added to the equipment per
T&I reports.
Determine corrosion sectors from process

flow diagrams.
Assign corrosion circuits from P&IDs.
Estimate corrosion rates for each piping
corrosion circuit.
Assign TMLs to corrosion circuits so that
the quantity and location will match the
expected corrosion class.
Review of corrosion rates greater than 5
mpy or equipment with remaining life less
than twice the OSI interval.
Review of process changes for impact on
OSI Program and adjust the TML's or
intervals as required and determine
Inspection interval based on the corrosion
rate.
Area
Inspector
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Process
Engineer
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Conduct baseline survey to obtain original

wall thickness measurement of new,
modified or previously unmonitored
equipment.
Obtain wall thickness measurement of the
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monitored plant equipment as per OSI due
reports and prepare OSI isometric drawings
of added piping and equipment.
Work Permit
Maintenance Activities
NDT
Technician
perform the required UT reading for the

TML and record thickness
Operation
Supervisor
Provide the required Work Permit
Maintenance
Engineer
Include providing the necessary manpower and

equipment (crane, man lift, scaffolding, etc) to
perform the required inspection activities and
rectify the highlighted deficiencies.
Documentations:
1. OSI isometric drawings.
2. TML readings.
The OSI coordinator shall document the above documentations in SAIF OSI module.
10- Dead leg survey and monitoring in plant areas:
Dead leg in the piping system is defined as the piping section where the flow is stagnant,
material has the potential for corrosion and when the length is longer than three times its
pipe diameter, or 1.22 m (4 ft) whichever is less. All dead legs shall be eliminated in the
design stage by modifying the piping system during project review. If the deal legs cannot be
eliminated at piping system, then YRD inspection Unit will monitor such dead legs through
the On- Stream Inspection (OSI) Program as per SAEP-1135.
For new projects and in case where a piping section is identified as dead leg and it is not
avoidable from a construction point of view, then it shall be added to OSI and a concurrence
letter shall be signed by:
-
Representatives from PMT (Project Manager)
Proponent (Engineering Division/Area Process Engineer)
Projects Inspection (Supervisor)
CSD Piping and Material Unit Supervisors.
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In normal operation, if a piping configuration is suspected to be a dead leg, then the plant
process engineer and YRD Corrosion engineer should be contacted to evaluate the case and
decide whether it is a dead leg or not. YRD has developed additional reference to help in
evaluating the dead leg conditions (Letter # KGP-92-09). If this piping configuration was
considered as dead leg, then the following activates will be made:
-
The dead leg will be added to OSI program.
The dead leg will be monitored every year for five (5) years.
After five (5) years of monitoring if no defect is found, then this dead leg can be
removed from OSI program.
If we found any metal loss even low corrosion rate, then the dead leg will be kept in
OSI program. In addition, this dead leg should be targeted for elimination if possible.
When pipe minimum thickness (tm) is reached, an inspection work sheet or logbook
entry shall be issued by area inspector to fix deficiency.
SAES-L-310
Design of Plant Piping
SAEP-1135
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Responsibilities:
Activities
Assigned to
Design
Activities
PMT
& new Assure that dead legs are eliminated in the design stage by
project
design modifying the piping system during the project review.
reviewer
Engineering Area process

Activities
engineer
YRD corrosion
engineer
Inspection
Activities
Remark
Identify all lead legs in his plant.

Provide technical assistance to clarify the dead leg criteria and
the addition / removal of dead leg to the OSI program
YRD
inspection Include the following:
unit supervisor
Highlight any dead leg, during construction phase, to PMT in
order to eliminate it if possible.
Assure that an inspection programs for inspecting dead legs is
established and all dead legs are being inspected and
monitored.
Issue an Inspection Worksheet or logbook entry is issued as
needed.
Inspection Field
Supervisor
Field Supervisor shall be responsible for the following:

Assure all dead legs are monitored by OSI program or any
other inspection methods.
Review inspection data with the responsible area inspector
and advise accordingly.
Assure inspection data is being reviewed, analyzed, and
added to SAIF.
Area inspector /
OSI coordinator
Area inspector / OSI coordinator shall be responsible for the

following:
Ensure all identified dead legs are monitored by the On

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Stream Inspection (OSI) program as per SAEP-1135.

Ensure appropriate inspection methods are used for each
dead leg.
Initiate an Inspection Work Sheet for any major findings and a
Logbook Entry for any minor findings.
Work
Permit
Area operation
supervisor
Maintenanc Maintenance
e Activates engineer
Include providing the necessary work permit

Documentations:
1. List of dead legs in the plant.
2. Dead leg worksheet or logbook issued by area inspector.
1. Equipment file
3. Upload the OSI reading for all identified dead leg into the SAIF program
11- Dummy leg survey and monitoring:
As the result of technical alert 002/01 dated 2/28/2001, all dummy legs in the plant, especially
in hydrocarbon service will be surveyed by the area inspector and any deficiencies will be
reported to area operations foreman for remedial action through IWS.
ALERT-01-002 Deficiency of Dummy leg support elbows
Responsibilities:
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Remark
Inspection
Activities
Area inspector
Perform the required survey and highlight any deficiency to

Area Operation foreman for implementation.
Maintenance
Activities
Area
Maintenance
engineer

Documentations:
1. Dummy legs survey for each plant.
2. Dummy legs worksheet or logbook issued by area inspector.
1. Equipment file
12- Chemical Injection Point Inspection:

Due to the risk of process leaks as a result of accelerated or localized corrosion at or near chemical
injection points, an inspection program will be initiated to monitor each chemical injection points.
Injection points include those for injecting corrosion inhibitors, PH control, anti-foam and methanol.
Injection Circuits
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For the purpose of monitoring, the Injection circuits shall begin at 300 mm (or 3D where D
is the nominal pipe diameter whichever is greater) upstream of the injection point and end at
the second change in the flow direction or 7.6 meters beyond the first change in flow
direction (whichever is less) downstream of the injection point.
Thickness Measurement Locations
The Thickness Measurement Locations (TML) within the injection circuits should be
located in the process piping at the below mentioned locations:
Beginning of the circuit upstream of the injection point.
Injection point 360 around the injection nozzle itself.
Impingement point on the process piping opposite the injection nozzle.
Downstream of the injection point defined as: D, 5D, 10D, midway between the
Injection point and the first change in direction (if they are more than 7.6 m apart).
First change in direction (elbow).
Connections (fittings) within the circuit.
At the end of the circuit downstream of the injection point as defined above.
00-SAIP-04 Injection Point Inspection Program
SAIF
System Assurance & Inspection of FacilitiesOSI Module
Dcumentations:
1. OSI isometric drawings.
2. TML readings.
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The OSI coordinator shall document the above documentations in SAIF OSI module
Responsibilities:
Activities
Assigned to
Inspection YRD
Activities inspection
unit
supervisor
Remarks
The Inspection Unit Supervisor shall be responsible for:
Assigning inspectors/technicians to gauge pipe wall thickness at the
injection point Thickness Measurement Location (TML).
Approve repair, modification or replacement recommendations for the
injection points.
Assure that the OSI inspection program is implemented in YRD facilities.
OSI
Coordinator
On-Stream Inspection (OSI) coordinator shall be responsible for:

Tracking and monitoring all injection points on the OSI drawings.
Highlighting the areas that are approaching T-min or area of concerns to
the corrosion engineer, the area inspector, and the field supervisor.
Add or delete OSI circuits and update the inspection interval on the SAIF
Program as requested by corrosion engineer.
Coordinate between NDT technician and area inspector to perform the
required UT readings and enter the readings in the SAIF program
Corrosion
Engineer
Update the OSI drawings.

Plant corrosion engineer shall be responsible for:
Identifying all the injection points in the plant (coordinate with the plant
process engineer in this task).
Reviewing/recommending modifications or replacement of injection
points.
Determine Inspection interval based on the corrosion rate
Evaluate the need to add/delete TML locations based on the corrosion rate
of the circuits
Saudi Aramco:
Coordinate with the area inspector to issue IWS if pipe spools require
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replacement due to internal corrosion

Area
inspector
Plant inspector shall be responsible for
Performing visual inspection as per 00-SAIP-75 guidelines.
Verifying the areas that are approaching T-min and issuing repair,
modification or replacement recommendations for review by the corrosion
engineer and the field supervisor and approval by the unit supervisor.
Assure that the OSI inspection program is implemented in his plant and
make sure that all OSI readings are updated in the SAIF program on
time(no Overdue)
NDT
Technician
Plant inspector/technician shall be responsible for:

Verifying the line number and location before taking the readings.
Taking the measurements as per the locations identified in this procedure.
Reporting any changes in the isometric drawing to the OSI coordinator.
Work
Permit
Operation
supervisor
Provide the required Work Permit
Maint.
Activities
Maintenance
Engineer
Include providing the necessary manpower and equipment (crane, man lift,
scaffolding, etc) to perform the required inspection activities and rectify
the highlighted deficiencies.
13- Corrosion Under Insulation Inspection and Repairs:

Insulated equipment and piping systems which are susceptible to Corrosion Under
Insulation (CUI) at YRD shall be identified and checked frequently through CUI Program.
Inspection frequency shall be as per SAEP 20. Susceptible systems shall be carefully
inspected visually. Visual inspection shall identify any sign of damaged insulation,
jacketing or deviations. It should be noted that CUI might take place without any sign of it
on the external surface of the insulation. NDT may be used in lieu of insulation removal.
Method and extent of NDT shall be approved by Inspection Department.
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Criteria for CUI program for piping systems:

Insulated piping systems shall be included in CUI inspection program if any of the followings
conditions apply:
Piping systems made of carbon steel and operating temperature between 25F (-4C)
and 250F (121C).
Piping systems made of carbon steel and operating temperature above 250F (121C)
or below 25F (-4C) but in intermittent service.
Piping systems made of austenitic stainless steel and operate between 100F (38C)
and 400F (204C).
Piping located in areas exposed to mist overspray from cooling water towers.
Piping systems located in areas exposed to steam vents.
Piping systems exposed to deluge systems.
Piping systems subject to process spills, ingress of moistures or acid vapors.
Dead legs and protrusions from insulted piping that operates at different temperatures of
the main line.
Steam traced piping systems that may experience tracing leaks, especially at tubing
fittings beneath the insulation.
Piping systems with deteriorated coating and wrapping, damaged insulation cladding, or
insulation that might be damaged by piping vibration.
CUI vulnerable Location for piping systems:

The below specific locations in piping systems susceptible to CUI may be exposed to CUI
more than the rest of the piping systems.
All penetrations or breaches in the insulation jacketing such as dead legs (vents,
drains, instrument tapping and similar items), pipe hangers and supports and steam
tracing tubing penetrations.
Irregular insulation surfaces such as valves and fittings.
Bolted-on shoes.
Terminations of insulation at flanges and other piping components.
Damaged or missing insulation jacketing or when the seams of the insulating jacketing
are located on the top of horizontal piping.
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Termination of insulation in a vertical piping.
Caulking that has hardened, has separated or is missing.

Bulges or staining of insulation or jacketing.
Low points in piping systems that have a known breach in the insulation system,
including low points in long unsupported piping runs.
Carbon or low-alloy steel flanges, bolting and other components under insulation in
high-alloy piping systems.
UT measurement windows in the insulation jacketing.
CUI program for equipment:
Insulated equipment shall be inspected for CUI if any of the following conditions apply:
Equipment operating between 25F (-4C) and 250F (121C).
Equipment operating above 250F (121C) or below 25F (-4C), but in intermittent operation.
Equipment protected by deluge water system.
CUI Vulnerable Location for equipment:
Some locations of Insulated vessels and tanks that are susceptible for CUI may be
exposed to CUI more than the rest of the equipment. Examples of highly suspect areas
include, but not limited to the following:
Stiffening rings and insulation support.
Areas around nozzles and man ways.
Areas around protrusions; like lifting lungs and platforms supports.
Samples of the CUI Vulnerable of corrosion under insulation as described above and
locations of damaged insulation found through visual inspection of the system shall be
inspected by either NDT or insulation removal. Quantities of inspection samples are as
shown in Table 1. Piping classification is per section 6.2 of API-570. All vessels and
tanks are to be classified as class 1
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Table1
Class
% of locations found with damaged

insulation to be inspected by NDT or
insulation removal
% of locations defined as susceptible

locations for CUI on this process to be
inspected by NDT or insulation removal
75%
50%
50%
33%
25%
10%
If the inspection of the selected locations revealed significant CUI, then the percentage of the
selected location shall be increased. If the system is known to have a good coating system,
or if the system has a good history from previous inspections for CUI, then the percentage of
the selected locations can be decreased up to 50% of the amounts given in Table 1.
00-SAIP-74 Inspection of Corrosion under Insulation and Fire proofing
SAEP-20
SAEP-1135
00-SAIP-75
SAES-N-001
Basic Criteria, Industrial Insulation
API 570
Saudi Aramco:
Equipment Inspection Schedule
Piping Inspection Code
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Responsibilities:
Activities
Assigned to
Inspection
Activities
YRD inspection Inspection unit supervisor shall be responsible for following:

unit supervisor Assure that an inspection programs for inspection CUI is
established and all susceptible systems for CUI are being
inspected and monitored.
Inspection
Field
Supervisor
Remark
Assure all susceptible systems for CUI are monitored.
Review inspection data with the responsible area inspector and

advise accordingly.
Assure inspection data is being reviewed, analyzed, and added
to SAIF.
Area inspector Area inspector shall be responsible for the following:

Assure that all identified susceptible systems for CUI are
monitored by the On Stream Inspection (OSI) program as per
SAEP-1135.
Ensure that the appropriate inspection methods are used for
each susceptible location for CUI as per the schedule.
Initiate a work sheet for any major findings and a logbook entry
for any minor findings.
Engineering
Activities
YRD corrosion Corrosion engineer shall be responsible for the following:

engineer
Identify all locations in the susceptible systems that are
susceptible for CUI.
Area process
engineer
Review all repair procedures and make sure that factors

promoting CUI are being eliminated if possible
Area process engineer shall be responsible for the following:

Verify if the existing insulation on piping or equipment is needed
either for energy conservation or personnel protection.
Work Permit Area operation Include providing the necessary work permit
supervisor
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man lift, scaffolding, etc) to perform the required maintenance
activities.
Documentations:
1. List of Susceptible Systems for CUI.
2. CUI worksheet or logbook issued by area inspector.
1. Equipment file
14- Thermograph inspection Survey of cold insulated equipment and piping
Thermograph Inspection of cold insulated drums, tanks and piping is carried out in order to
determine the damaged insulation and hot spots. These areas will be later added to T&I
scope to remove the insulation at the damaged areas and hot spot areas for visual and NDT
inspection and remedial action.
None
Responsibilities:
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to
Inspection Activities
YRD inspection
unit supervisor
Include assuring that inspection unit has a qualified

inspector who can perform thermograph inspection
survey.
Inspection Field
Supervisor
Assure all susceptiblesystems for damaged

insulation are monitored.
Review inspection data with the responsible

Qualified Inspector and area inspector and
advise accordingly.
Assure inspection data is being reviewed,
analyzed, and added to shared files and
equipment file.
Work permit
YRD Qualified
Inspector
Include performing the Thermograph survey and

report any deficiency.
Area Operation
Include providing the necessary work permit and

inform maintenance to start maintenance activities.
Supervisor
Maintenance Activates
Area Maintenance Provide technical support as needed

Engineer
Provide the necessary manpower, material and
perform the required maintenance activities.
Documentations:
Thermograph inspection survey report. The inspector shall document this report in:
1. Equipment file
15- Cathodic Protection System Inspection
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YRD Operation/Inspection Unit will conduct monthly and annually surveys to monitor the
cathodic protection (CP) systems as specified in SAEP-333 and SAIP-02. The CP system
must be monitored to ensure that equipment or structures receive adequate protection.
Monitoring surveys for tank bottoms and in-plant buried piping will be conducted annually by
electrical inspection unit. The survey data shall be reviewed, analyzed and carried out
recommendations for corrective action.
Anode bed monitoring and maintenance:
Evaluate the performance of each anode bed annually prior to the scheduled annual potential
survey. The evaluation includes measuring the current output for each individual impressed
current/galvanic anodes and current in the negative cables. Measure the current output
From the voltage drops across the shunts if they are installed at the anode cable
terminals inside the anode junction boxes
By a DC clamp-on-ammeter, if no shunts are available
Calculate an estimate of the service life of the anode beds. For single or multiple
negative cables, measure the current in each cable as above.
For junction box, annually check will be conducted for all anode junction box connections
and fittings for cleanliness and tightness. During annually check, perform any required
maintenance as follows:
Take apart all connections and bolted fittings and clean with an approved safety solvent.
Apply Burndy Penetrox E oxide inhibiting compound (or equivalent) to all
cables and connections. When finished, reinstall them.
Seal or reseal all conduit openings with Duxseal compound.

Inspect, repair, or replace the door seals.
Record all anode bed readings during the annual check on the relevant data sheet show in
SAEP-333A, appendices FK.
Rectifier maintenance and monitoring procedures:
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In YRD, there are two types of rectifiers oil cool and air cool rectifiers. Oil cool rectifier is
represented at DGA and air cool rectifier at Utilities. These rectifiers are required two types
of inspection monthly and annually inspections.
Monthly inspection:
Either Operations or Maintenance personnel who normally visit the site on a regular
basis for purposes other than those relating to cathodic protection can perform
these procedures.
Check rectifiers on a monthly basis and record the output volts and amps.
Record the rectifier output data on the attached data sheet.
Report immediately any abnormal rectifier operation to the Inspection Unit.
Annual inspection:
Record rectifier output volts and amps.
Verify the reading with a portable meter
Visually inspect the cabinet, terminals, and components for any damage.
For oil cool rectifier only, check the oil level, temperature and perform
sample check as follows:
1. Open the drain spout and collect approximately one liter of oil in a clear glass
container. If sediment, sludge, or water drains with the oil during sampling, continue
draining until the contaminant has been flushed out. Then collect approximately one
liter of oil. If the sediment has not been flushed out after four liters of oil have
drained, the rectifier should be completely drained and filled with new oil.
2. If the oil is dark or cloudy or appears to be full of suspended particles, it should be

replaced.
3. Dispose of old oil in an environmentally approved manner.
Adjust the rectifier sitting as required in order to ensure adequate protection.
Record all data taken during the annual rectifier check on the data sheet shown in
SAEP-333A, appendix J, pages 12.
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GI 428.003
SAES-X-600
SAEP-333 Cathodic
SAEP-333A
Cathodic Protection Monitoring Procedure

Cathodic Protection of In-Plant Facilities
Protection Monitoring Procedure
Cathodic Protection Monitoring Appendices FK
Documentations:
List of CP Systems at YRD:
CP systems monthly status reports.
annual CP survey report summarizes the CP status of all protected structures
The, all CP system performance, and includes recommendations to eliminate

deficiencies.
Issued CP worksheet or logbook.
Annual CP survey report to CSD.

1. Equipment file
Responsibilities:
Activities
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YRD inspection Inspection unit supervisor shall be responsible for the following:
unit supervisor Assure that an inspection programs for CP is established and being
inspected and monitored.
Area foreman Area foreman shall be responsible for the following:
Ensure that All CP systems are being checked.
Electrical
maintenance
supervisor
Ensure that CP system is in good operating condition.
Inform KGP inspection unit for any abnormalities.
Electrical maintenance supervisor shall be responsible for the

following:
Ensure that All CP systems are being monthly checked.
Ensure that all electrical technicians know how to obtain the
rectifier DC Volt/Ampere output readings at the area under his
authority.
Inform YRD inspection unit for any abnormalities.
Area electrical Area electrical technician shall be responsible for the following:
technician
Conduct the CP rectifier monthly check and record output data in
data sheet.
Report any abnormal rectifier operation to YRD inspection unit.
Forward the rectifier output reading to YRD inspection unit on a

monthly basis.
Area operator Area operator shall be responsible for the following:
Inspection
Field
Saudi Aramco:
Report any abnormal rectifier operation to Area foreman.
Assure all CP systems are monitored.
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Review inspection data with the responsible electrical inspector

and advise accordingly.
Assure inspection data is being reviewed, analyzed, and added to
shared files, equipment file and SAIF.
Area electrical
inspector
Area electrical inspector shall be responsible for the following:
Conduct the CP rectifier, junction box and anode bed annually

survey and record output data in data sheets.
Report any abnormality on the CP rectifier, junction box and

anode bed.
Work Permit
Area operation Area operation supervisor shall be responsible for the following:
supervisor
Provide the necessary work permit and inform maintenance to
start maintenance activities.
Engineering
Activities
YRD corrosion
engineer
Review monthly and annually reports and recommend solutions for

any abnormalities.
Maintenance
Activates
Maintenance
engineer

man lift, scaffolding, etc) to perform the required maintenance
activities.
6- Monitoring of Corrosion Monitoring system (CMS)
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Piping systems are generally subject to both internal and external corrosion. The internal
corrosion is considered to be challenging as well as expensive in practice. It has been
observed that internal corrosion could potentially reduce the pipe wall thickness much more
than external corrosion. In general, it becomes highly critical to mitigate internal corrosion
and reduce the risk of leakage in piping system. For that, YRD has installed corrosion
monitoring system to monitor internal corrosion and corrosion inhibitor performance inside
piping systems. COSASCO 2" corrosion monitoring assemblies are the CMSs, which are
installed in YRD. This CMS is designed to monitor corrosion behavior on line.
COSASCO 2" CMS can be installed and retrieved by using the following equipments:
1- RBSA retrievers
2- Service valves
3- Bleed valve and a pressure gauge to allow the operator to monitor the internal
pressure during use
These equipments are designed to install and retrieve the COSASCO 2" corrosion
monitoring assemblies... safely, without shutdown. But in order to complete retrieving or
installing activities safely comply with the below requirements:
1- Safe operation requires a minimum of 2 trained operators.
2- Do not use retrieval equipment unless you have been trained in its safe operation.
3- If it has been longer than 90 days since your last operation, you should review the
manual and first practice on a dummy fitting prior to use.
4- Make sure you have complied with all plant safety requirements and
environmental regulations.
5- Identify the type media, its pressure and temperature.
6- Review material safety data information on the media prior to operation.
7- Insure you have all the required safety equipment for the given media, "i.e. hard hat, safety
glasses, protective clothing, safety gloves, respirator, spill safety equipment, etc...
8- Any actions which could vary system pressure such as surges caused by opening and
closing of valves and chokes should be delayed until completion of retrieval operations.
9- Insure you have enough clearance for safe operation.

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10- Note wind direction prior to starting operations involving hazardous products.
Corrosion Monitoring OI&MM
Project Specification for Corrosion Monitoring System
Responsibilities:
Activities
Assigned to
Inspection
Activities
YRD inspection
supervisor
Remark
unit Inspection unit supervisor shall be responsible for the
following:
Assure that an inspection programs for Monitoring of CMS
is established and all CMSs are being inspected and
monitored.
Engineering YRD corrosion engineer Corrosion engineer shall be responsible for the following:
Activities
Conduct monthly survey through PI system.
Work Permit
Review monthly and annually reports and recommend

solutions for any abnormalities.
Inform Area Forman/operation supervisor if there is

any abnormalities or any materials replacement are
needed.
Area Forman/operation Include Providing the necessary work permit and inform
supervisor
Maintenance Maintenance engineer

Activities
Include providing the necessary manpower, material and

equipment (crane, man lift, scaffolding, etc) to perform
the required maintenance activities.
Documentations:
1- List of CMSs at YRD.
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2- CMSs monthly status reports.

3-
CMSs performance, and includes recommendations to eliminate deficiencies.

1- Equipment file
2- Equipment file in the shared folder
3- Update the SAIF program if required
17- External civil inspection of foundations, footings, sleepers and structures:

External civil inspection of all foundations, footings, sleepers and pedestals of all equipment,
plant piping and structural supports are conducted as per the guidelines given in the
referenced procedures
00-SAIP-75
SAEP-309 Inspection
SAES-A-114

of Community and Operations Support Facilities
Excavation and backfill
Responsibilities:
Activities
Saudi Aramco:
Assigned to
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YRD inspection Assure that the civil inspection program is implemented for all
unit supervisor
YRD electrical equipment.
civil Inspector
Perform External civil Inspection on all industrial plant civil

structure and Operation Support Facilities.
Review maintenance work schedule and inspect the
performed civil work as needed.
Report immediately to Operations foreman all deficiencies
which are found during the civil inspection survey through
Log book entry or Inspection worksheets as needed.
Follow up with the area maintenance engineer to rectify
these deficiencies.
Maintenance
Activities
Area maintenance Rectify the reported deficiencies in his area.

engineer
Work Permit
Area operation
supervisor
provide the necessary work permit (as needed)
Documentations:
1. Issued civil inspection checklist
2. Inspection worksheets or Log Book Entry if needed.
3. Monthly status report with clear tracking system detailing all open worksheets and
items to operations in a monthly basis.
The civil inspector shall file the above documentations on:
1- Shared folder
2- Inspection unit file room
3- Upload it into SAIF system (Inspection Worksheet only).
18- Inspection of Plant Buildings (Civil Inspection).
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Visual civil inspection of plant buildings such as OME, PIB, Substations, Lift stations etc shall be
conducted as per guidelines given in the civil section of EIS and the below engineering
procedure.
A concrete database is being created and will be uploaded in the SAIF system. The database
will contain all the equipment and piping foundations, footing and sleepers and all fireproofing
in the plant. The concrete foundations will be classified as per the grading given in SAEP-309
for concrete and grouting.
SAEP-309 Inspection
SAEP-S-020
Oily Water Drainage System
SAES-S-010
Sanitary Sewers
00-SAIP-75
of Community and Operations Support Facilities
Responsibilities:
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Remark
Inspection Activities Civil Inspector
Perform the external civil inspection as per the

inspection schedule.
Perform internal inspection for the lift stations
during scheduled T&I or as per operation
request.
Work Permit
Area operation supervisor Include providing the necessary work permit

and inform maintenance to start maintenance
activities.
Maintenance
Activates
Maintenance engineer

perform the required maintenance activities.
Documentations:
1. Civil Inspection Report which shall be filed in the inspection filling room and the shared folder
2. Update the SAIF program.
19- Concrete fireproofing and proprietary fire proofing survey:

Fireproofing on static equipment and piping systems shall be considered as insulation.
Equipment furnished with fireproofing shall be inspected for corrosion under fireproofing.
For Static Equipment Skirts, Saddles and Elevated pipe Supports
Thorough visual inspection shall be performed. Areas near moisture and water entry points
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shall be given more attention during inspection. Any crack in the fireproofing shall be
evaluated to find out if it is indicating any sign of corrosion. Inspection windows might be
made to verify any external sign of corrosion under fireproofing. If corrosion is found then
the fireproofing shall be removed to expose all corroded area.
For Structures and Pipe Racks
Visual inspection shall be performed to find out any external sign of corrosion under
fireproofing. Inspection windows in form of horizontal stripes should be made if deemed
necessary. They should intersect cracks at random locations. If corrosion is found, then
all corroded area shall be exposed.
If any NDT can be applied to inspect the equipment under fireproofing for corrosion, then
inspection windows or stripes should not be made.
00-SAIP-74 Inspection of Corrosion under Insulation and Fireproofing
Responsibilities:
Corrosion under insulation (CUI) and corrosion under fire proofing (CUF) share the
same responsibilities. Follow the responsibility section of the CUI program.
Documentations:
The civil inspector shall issue a report to document his findings during the annual
survey of the fire fireproofing in the plant. This report should be stored in the:
1- Equipment file
3- Upload it into SAIF system(Inspection Worksheet only)
20- External Inspection of Electrical Equipments:
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An annual external inspection for all electrical equipment should be conducted and
deficiencies shall be reported for area operation foreman to rectify. The internal
inspection of plant equipment shall be made as required at installation, upon request
or during scheduled test and inspections (T&Is). The external inspection of the below
electrical equipment in the plant shall be conducted annually:
Conduit systems, cable trays and cable systems for support and continuity.
Enclosures and junction box for covers, conduit seals and drains.
Electrical Equipment such as motors for physical damage, oil leaks, and
overheating.
Integrity of the ground grid system and equipment grounds.
The following inspections of all Operations Support Facilities (OME, PIB,

substation, etc) shall be conducted annually:
Emergency , Exit lighting, Emergency generators and transfer switches

Lighting, Lighting Systems, Wall Devices and Distribution Panels
Transformers and Switch racks
Junction Box Enclosures, Cable and Conduit systems
Substations equipment
Manholes/Duct Banks
Battery Rooms and Ground System
00-SAIP-51
Electrical Inspection
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15-SAIP-50
Inspection Procedure for Conduits and Cable seals
15-SAIP-51
Inspection Procedure for PVC Coated Rigid Steel Conduit
16-SAIP-11
Medium and High Voltage Oil Switches
SAEP-136 S. Aramco Management of Electrical Equipment Obsolescence program.
DE-014949
Electrical Equipment Inspection Schedule (EIS) for Industrial Plant
DE-093684
Electrical Inspection Schedule for Community and Ind. Support Facilities
00-SAIP-75
SAES-P-101
Regulated Vendors List for Electrical Equipment
SAES-P-103
UPS and DC Systems
SAES-P-104
Wiring Methods and Materials
SAES-P-107
Overhead Distribution Systems
SAES-P-111
Grounding
SAES-P-113
Motors and Generators
SAES-P-114
Power System and Equipment Protection
SAES-P-116
Switchgear and Control Equipment
SAES-P-119
Onshore Substations
SAES-P-121
Transformers and Reactors
SAES-P-123 Lighting
SAES-P-126
Saudi Aramco:
Power Monitoring and Control System
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Responsibilities:
Activities
Assigned to
Inspection
Activities
YRD inspection
supervisor
Electrical Inspector
Remark
unit 1. Assure that the electrical inspection program is
implemented for all YRD electrical equipment.
2. Perform External Electrical Inspection on all
industrial plant electrical equipment and Operation
Support Facilities.
3. Review maintenance work schedule and inspect
the performed electrical work as needed.
4. Report immediately to Operations foreman all
deficiencies which are found during the electrical
inspection survey through Log book entry or
Inspection worksheets as needed.
5. Follow up with the area electrical technicians to
rectify these deficiencies.
6. Perform internal inspections in all open electrical
equipment during T&Is.
7. Review all electrical engineering design package
and inspect all new electrical installation in the
plant.
Maintenance
Activities
Area electrical technician Rectify the reported deficiencies in his area.
Work Permit
Area operation supervisor provide the necessary work permit (as needed)
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Technical
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Area Electrical Engineer Provide technical support as needed to clarify the

related standards and to rectify deficiencies
Documentations:
1- Issued electrical inspection checklist
2- Inspection worksheets or Log Book Entry if needed.
3- Monthly status report with clear tracking system detailing all open worksheets and
items to operations in a monthly basis.
The electrical inspector shall file the above documentations on:
1- Shared folder
2- Inspection unit file room
3- Upload it into SAIF system (Inspection Worksheet only).
21- Thermography inspection for electrical equipment
Breaker panels, switchgear, motor control centers, and bus bar connections. The infrared
camera is a predictive maintenance device that can reveal loose connections, unbalanced
loads / phase problems and overloaded circuits.
The procedure of conducting Thermography Inspection for electrical equipment is included in:
00-SAIP-51-5.9
Saudi Aramco:
Electrical Inspection
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Responsibilities:
Activities
Assigned to
Remark
Inspection
Activities
Electrical Inspector
Performing the Thermography survey and report any

deficiency to the plant foreman. The inspector
should follow up on rectifying the deficiency by
issuing an Inspection worksheet or Log Book Entry
item. Up on completion the inspector should close
the related IWS.
Maintenance
Activities
Area Maintenance
engineer

equipment to rectify the deficiency.
Work Permit
Area operation
supervisor
Include providing the necessary work permit
Technical support Area Electrical

Engineer
Provide technical support as needed to clarify

the related standards and to rectify deficiencies
Documentations:
1- Infrared camera report
2- Inspection Work Sheet or Log Book Entry if needed
The inspector shall file the above documentations in:
1- Shared folder
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2-
Inspection unit file room
3-
Upload it into SAIF system (IWS only).
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22- Issuing and monitoring Inspection Worksheets and Log Book Entry
Refer to SMS # 5.7
23- Technical Alerts Tracking System:
Technical alerts tracking system is implemented as per the guidelines indicated in SAIP-77.
This system should be established to track all the technical alerts that are published by S.
Aramco. YRD technical alerts coordinator should assign the alerts to the right team
(electrical, mechanical, instrument ...) to evaluate them and take the required action.
SAIP-77
Technical Alerts Engineering Services Technical Alerts
Technical Alert Implementation and Tracking Program
Responsibilities:
Activities
Establish technical
alerts tracking system
Saudi Aramco:
Assigned to
Remark
YRD technical alerts

The system should be implemented according
coordinator / Inspection to SAIP-77
Unit supervisor
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Track and update the

engineering Services
Technical Alerts
YRD technical alerts

coordinator
Any new technical alert should be tracked.
Evaluate the technical

alerts and perform the
right action
The assigned team/ unit Mechanical, electrical, relief valve, piping,

leader
HVAC and instrument.
Documentations:
The technical alerts coordinator shall document the evaluation and action from the assigned team.
KGP technical alerts tracking system available in the KGP shared folder
24- Positive Material Identification of existing and new material:

In order to make sure that the material used in fabricating pressure vessels and components,
valves are of genuine materials, Positive material identification tests should be conducted on
all new alloy steel materials for new construction, repair and replacement in accordance with
the following Engineering Standards and inspection procedures.
SAES-A-206
Positive Material Identification
00-SAIP-07
Positive Material Identification requirements
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Responsibilities:
Activities
Assigned to
Remark
Inspection
Activities
YRD inspection unit

supervisor
Assure that a PMI program is developed and implemented

based on 00-SAIP-07.
YRD Area Inspector
Work Permit Area

Forman/operation
supervisor
Perform PMI testing.
Verify elements as per table 1 in SAES-A-206.
Inform Area Forman/operation supervisor if there is any

abnormalities or any materials replacement are needed.
Include Providing the necessary work permit and inform

Maintenance Maintenance engineer Include providing the necessary manpower, material and
Activities
equipment (crane, man lift, scaffolding, etc) to perform the
required maintenance activities.
Documentations:
1- Material data sheet.
2- Output results of reading.
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1- Equipment file
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SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

YANBU REFINERY INSTRUCTION MANUAL

YRIM No.: 1156.00

SUBJECT: YRD Inspection Program

Engineering Inspection Unit

Saudi Aramco Loss Prevention Policy

Operate and maintain Company facilities to assure safe operations;

Report all incidents, review performance and communicate progress;

Promote off-the-job safety and community awareness, and

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

SUBJECT: YRD Inspection Program

YRIM No.: 1156.00

Engineering Inspection Unit

Purpose & Objective

2. Owner or Champion: YRD Engineering Inspection unit is the owner of these

This comprehensive inspection document contains several inspection procedures/programs

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

SUBJECT: YRD Inspection Program

YRIM No.: 1156.00

Engineering Inspection Unit

Training & Competency

YRD SMS: Inspection Programs

ELEMENT 5 ASSET INTEGRITY

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

SUBJECT: YRD Inspection Program

YRIM No.: 1156.00

Engineering Inspection Unit

YRD List of Inspection Programs:

1- Relief valve installation, inspection and testing:

SAEP-317 Testing & Inspection of Shell & Tube Exchangers

Industrial Radiation Safety

Magnetic particle examination of welds and components

Liquid penetrant examination of weld and components

of the remaining strength of corroded pipes

requirements for pressurized equipment

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

YRIM No.: 1156.00

SUBJECT: YRD Inspection Program

Engineering Inspection Unit

Guidelines for Process Equipment Inspection

Inspection of Air cooled Exchangers

Retirement thickness of In-plant Piping

Process Design of Trays and Packing

Design of Small Tanks

Design Criteria of Shell and Tube Heat Exchangers

Design Criteria of Air-Cooled Heat Exchangers

System Design Criteria of Flares

Selection Requirements for Industrial Coatings

Installation Requirements Castable Refractories

Manual Ultrasonic thickness testing

Pressure Vessel Inspection Code

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

SUBJECT: YRD Inspection Program

YRIM No.: 1156.00

Engineering Inspection Unit

Inspects the static equipment during receiving and storing in

Inspects the static equipment during installation.

Inspects and witness the hydrotest and lay up of static

Include performing the required NDT test and witnessing

Include providing the necessary manpower and equipment (crane,

Include providing the necessary work permit and initiating

SAUDI ARAMCO OIL COMPANY (Saudi Aramco)

SUBJECT: YRD Inspection Program