This area of investigation was directed toward addressing the impact of inspection and monitoring practices on the Safaniya Utility Units’ Asset Management Program. Table 3-9 lists the issues addressed and the resultant findings.
INSPECTION AND MONITORING ISSUES | PLANT INTEGRITY MANAGEMENT
|What mechanisms are used to determine requirements for inspection activities?||Piping is continuously on-line inspected; fixed equipment during planned or unplanned shutdown, turn around. The frequency of inspection is determined by the Inspection Management Data Base System based on the results of previous inspections. The criteria and the frequency is based on Engineering Procedure SAEP-1135 On-Stream Inspection Administration.|
|What guidelines are used to determine requirements for monitoring damaging mechanisms (such as corrosion, vibration, flow conditions causing erosion or corrosion etc.); and also for mitigation of these?||Saudi Aramco (SA) Std. SABP-A-036 for monitoring corrosion by corrosion coupons, checking vibration. SAES-L-133: Corrosion Protection Requirements for Pipelines, Piping and Process Equipment.|
|Are all corrosion monitoring and inspection locations/datum points clearly identified within engineering drawing (P&IDs, isometrics) and within applicable workpacks?||Yes|
|What guidelines are there for carrying out and reporting “opportunity” inspections, e.g. as part of unplanned equipment downtime?||None|
|What procedures are used to inspect normally inaccessible areas of plant?||Scaffolding for higher elevations|
|How are the requirements and qualifications of
|Promotions for inspectors are based on the number of licenses they earn|
|What is the criterion used to certify inspectors for an inspection process? Are these issued by International Certification Agency or by the plant?||None; Certificates are based on Aramco testing standards that are based on American National Standards Institute (ANSI), American Petroleum (API) Standards as well as those issued by National Association of Corrosion Engineers (NACE).|
|What procedures are used to determine inspection Thickness Measurement Locations?||Based on Aramco Guideline SAEP-1135, On-Stream Inspection Administration guidance.|
|How are inspection anomalies managed? – Is there a defined procedure highlighting the actions required for each level of anomaly?||By creating a worksheet from which a Work Order is created by Maintenance. Yes, there exists a procedure.|
|Does minimum design thickness data exist for all vessels? If not, what procedures are applied?||Yes, All vessels have U1-A forms.|
|What are the minimum acceptable wall thicknesses for piping systems? Have these been calculated according to a recognized standard e.g. American Society of Mechanical Engineers (ASME) B31.3?||Based on Piping Standard ASME B31.3|
|Is appropriate consideration given to the limitations of inspection and monitoring techniques during evaluation of the data?||yes|
|What procedures are in place to define the requirements for inspection deferrals?||None, as there are no chemicals or other reasons that may require inspection deferral.|
|Does the asset produce an annual Integrity
Statement or Integrity Status Report?
|Inspection Department issues an annual report, e.g., Tanajib Plant Annual Corrosion Activities Report NATSD/NACID/SONC&IU-111/10|
|Are any areas of plant specifically excluded from inspection or monitoring programs?||No|
|Are corrosion control matrices employed to monitor and control the main corrosion threats?||Yes|
|Are corrosion inhibitor dosing levels correlated with fluid volumes to optimize dosing?||Yes|
|How are corrosion rate excursions investigated
(and correlated with production/chemical data)?
|By performing analysis of all influencing variables.|
|How are remedial actions achieved? For example what procedures are used to optimize inhibitor treatments?||By testing in lab., By trial and error for optimizations.|
|What procedures are in place to ensure that corrosion probes (e.g. ER or LPR) are functioning?||None|
|How often are corrosion coupons retrieved for weight loss assessment and examination?||Quarterly|
|What procedures and frequencies are used for the management of corrosion probe data?||With the plant software|
|What procedures are used to evaluate the root cause of corrosion incidents and process upsets leading to increased monitored corrosion rates?||By Failure and Process Parameters analysis|
|What procedures are in place to examine insulation systems and prioritize refurbishment and inspection programs?||Aramco Guideline 00-SAIP-74 Corrosion Under Insulation Inspection Procedure SAIP-74 compares very well with the inspection procedures currently used in refining and chemical industry, and incorporates elements of API and NACE documents. The procedure is adequate for the intended purpose of CUI monitoring.|
|Have non-invasive techniques for CUI been successful in detecting areas of damage or wet insulation?||There was no evidence that non-invasive techniques such as Pulsed Eddy Current had been used for monitoring CUI.|
|Are paint specifications applied for repainting programs – do these reflect current best- practice?||Yes|
|Are paint inspectors employed to oversee repainting works? Are the certified by SSPC (NACE) or by other authority?||Yes, by NACE|
|Are written procedures in place for all inspection and monitoring activities?||Yes|
|How is the Inspection History of each item stored – electronic or otherwise? Is it easily retrievable?||Electronic. Easily retrievable, reviewed List of TMLs for Equipment Dead Leg 09 (G244A), List of TMLs for Equipment 16″ Gas Header, List of TMLs for Equipment Injection PT 01 (30″ Utility Discharge Line, and List of TMLs for Equipment TMLS\ 06 SH 02 (Formation Water Tank Shell)|
The key findings from the Inspection and Monitoring area are summarized as follows:
• The many corrosion issues and challenges within the Utility Units are well known.
Notwithstanding those issues and challenges, the Inspection and Testing Department in conjunction with the Lead Engineer, NA Corrosion & Inspection are performing inspections and corrosion reviews that conform to best practice. Safaniya’s inspection program is based on the Saudi Aramco Standards and Guidelines (e.g., Aramco (SA) Std. SABP-A-036, SAES-L-133, etc.).
These Standards and Guidelines are based on API, ASME, and NACE documents, and are adequate for Safaniya’s requirements. The Inspection Department follows the guidelines in these programs, and they are in full compliance with the requirements specified.
• Invasive techniques for monitoring corrosion under insulation (CUI) are used for detecting areas of damage or wet insulation.
Recommendation: It is recommended that Safaniya investigate the capabilities of pulsed eddy current to monitor CUI cost effectively, eliminating the need to remove insulation.