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Engineering Procedure SAEP-343 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

7 July 2015

Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards Table of Contents 1 2 3 4 5 6 7

Scope................................................................... 2 Purpose................................................................ 2 Conflicts and Deviations....................................... 2 Applicable Documents.......................................... 3 Definitions and Abbreviations............................... 5 Instructions......................................................... 12 Responsibilities................................................... 22

Appendix 1 - Decision Tree for Performing RBI........ 27 Appendix 2 - RBI RASCI Chart................................. 28 Appendix 3 - RBI Process for In-House Assessment.......................... 29 Appendix 4 - RBI Process for Service Providers....... 30 Appendix 5 - RBI Workflow for Tracking Recommendations............................... 31 Appendix 6 - Corrosion Loop Development Workflow........................ 32 Appendix 7 - RBI Task List........................................ 33 Appendix 8 - Description of RBI Tasks..................... 34 Appendix 9 - Sources of Site Specific Data and Information........................... 46 Appendix 10 - Inspection Effectiveness Tables........ 48 Appendix 11 - RBI Validation Form........................... 68 Appendix 12 - RBI Validation Form Instructions....... 69 Appendix 13 - Environmental Sensitivity................... 70 Index......................................................................... 72

Previous Issue: 21 August 2013 Next Planned Update: 21 August 2018 Revised paragraphs are indicated in the right margin Primary contact: Kakpovbia, Anthony Eyankwiere (kakpovte) on +966-13-8801772 Copyright©Saudi Aramco 2015. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

1

2

3

Scope 1.1

This engineering procedure provides minimum requirements for conducting risk based inspection assessments on stationary equipment in all existing and planned Saudi Aramco facilities based on API RP 580.

1.2

This procedure also provides guidelines to determine the type of RBI assessment and process units that shall be covered by RBI assessment.

1.3

This procedure outlines when initial and evergreen RBI assessment shall be conducted.

1.4

This SAEP applies to 1.2.1

In-plant static equipment

1.2.2

Piping

1.2.3

Storage tanks

1.2.4

Pressure relieving devices

1.2.5

Off-Plot Piping

1.2.6

Offshore facilities

Purpose 2.1

To assure that Saudi Aramco systematic evaluation process for Risk Based Inspection (RBI) assessment is well defined.

2.2

Roles and responsibilities for RBI assessment activities in Saudi Aramco are outlined and auditable.

2.3

RBI assessment recommendations and implementation are uniformly documented for the purpose of corporate tracking and auditing.

2.4

Adequate resources are provided for RBI assessment.

2.5

Process and deliverables when utilizing Service Providers to perform RBI assessment is clearly defined.

Conflicts and Deviations 3.1

Any conflicts between this Procedure and other applicable Saudi Aramco Engineering Procedures (SAEPs), Saudi Aramco Engineering Standards Page 2 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

(SAESs), Saudi Aramco Materials System Specifications (SAMSSs), Saudi Aramco Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing through the Manager, Inspection Department of Saudi Aramco, Dhahran. 3.2

4

Direct all requests for deviations from this Procedure in writing in accordance with SAEP-302 and forward such requests to the Manager, Inspection Department of Saudi Aramco, Dhahran.

Applicable Documents Except as modified by this SAEP, applicable requirements in the latest issues of the following industry Codes, Standards, and Practices shall be considered an integral part of this procedure. 4.1

Saudi Aramco Documents Saudi Aramco Engineering Procedures SAEP-20

Equipment Inspection Schedule

SAEP-43

Corrosion Management Program Deployment for Existing facilities

SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

SAEP-308

Plant Inspection Unit Assessments

SAEP-325

Inspection Requirements for Pressurized Equipment

SAEP-372

Plant Inspection Performance Index (PIPI)

SAEP-1135

On-Stream Inspection Administration

Saudi Aramco Engineering Standards SAES-A-135

Establishment of On Stream Inspection

SAES-L-105

Piping Material Specifications

SAES-L-133

Corrosion Protection Requirements for Pipelines, Piping and Process Equipment

SAES-L-310

Design of Plant Piping

Saudi Aramco Best Practice SABP-A-033

Corrosion Management Program (CMP) Manual

Page 3 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Saudi Aramco Engineering Report SAER-5437

Guidelines for Conducting HAZOP Studies

Loss Prevention Department Saudi Aramco Safety Management Guide 4.2

Industry Codes and Standards American Petroleum Institute API STD 510

Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and Alteration

API STD 570

Piping Inspection Code - Inspection, Repair, Alteration, & Rerating of In-service Piping Systems

API RP 571

Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

API RP 580

Risk-Based Inspection

API RP 581

Risk-Based Inspection Technology

API RP 584

Integrity Operating Windows

API STD 653

Tank Inspection Repair, Alteration, and Reconstruction

API RP 750

Management of Process Hazards

API RP 752

Management of Hazards Associated with Location of Process Plant Buildings

API RP 1160

Managing System Integrity for Hazardous Liquid Pipelines

American Society of Mechanical Engineers ASME SEC V

Nondestructive Examination

ASME SEC VIII

Rules for Construction of Pressure Vessels

ASME B31.3

Process Piping

ASME B31.4

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31.8

Gas Transmission and Distribution Piping Systems, 2012 Edition

ASME B31.8S

Managing System Integrity of Gas Pipelines

Page 4 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

American Society of Testing Materials ASTM G46

Guide for Examination and Evaluation of Pitting Corrosion

National Board of Boiler and Pressure Vessel Inspectors NB-23

National Board Inspection Code

U. S. Code of Federal Regulations OSHA 29 CFR 1910.119 5

Process Safety Management

Definitions and Abbreviations 5.1

Definitions Asset Integrity Management System: Modern management tool to ensure that assets are safely performing their optimum planned functions over their life cycle starting from the design phase up to the decommissioning phase. Thus, AIMS is a proactive risk based holistic and integrated management system covering its entire life cycle for effective implementation of coherent work processes ensuring combined mechanical, functional and operational integrities. Components: Parts that make up a piece of equipment or equipment item. For example a pressure boundary may consist of components (pipe, elbows, nipples, heads, shells, nozzles, stiffening rings, skirts, supports, etc.) that are bolted or welded into assembles to make up equipment items. Comprehensive OSI Review: Detailed review of On-stream Inspection (OSI) program per SAEP-1135. Consequence: Outcome from an event. There may be one or more consequences from an event. Consequences may be positive or negative. However, for the purpose of this document consequence will mean the negative outcome of any event. Consequences may be expressed qualitatively or quantitatively. Corrosion Loop: Section of a plant defined mainly on the basis of similar process conditions, materials of construction, or similar active/potential damage or fouling mechanisms. Corrosion Management Program (CMP): A Risk-based, structured and integrated program aimed at proactively preventing corrosion in operating facilities without compromise to safety and the environment. Damage Mechanism: A process that induces micro and/or macro material changes over time that is harmful to the material condition or mechanical properties. Page 5 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Damage mechanisms are usually incremental, cumulative, and, in some instances, unrecoverable. Common damage mechanisms include corrosion, stress corrosion cracking, creep, erosion, fatigue, fracture, and thermal aging. Deterioration: The reduction in a material's ability to perform its intended purpose. This can be caused by various deterioration mechanisms (e.g., thinning, cracking, mechanical). Damage or degradation may be used in place of deterioration. Degradation Mechanism: See Damage Mechanism. Equipment: An individual item that is part of a system. Examples include pressure vessels, relief devises, piping, boilers and heaters. ES RBI Team: RBI team that includes members from Engineering Services led by Inspection Department, performing QA/QC of RBI process in Saudi Aramco. Event: Occurrence of a particular set of circumstances. The event can be singular or multiple. The probability associated with the event can be estimated for a given period of time. Evergreening: Is the process of updating the initial RBI assessment due to changes affecting the RBI results, e.g., additional inspections, process or mechanical changes. External Event: An event beyond the direct or indirect control of management and staff at the facility. External events may result from forces of nature, acts of God or sabotage, or such events as neighboring fires or explosions, neighboring hazardous material releases, electrical power failures, tornadoes, lightening, earthquakes, and intrusions of external transportation vehicles, such as aircraft, ships, trains, trucks, or automobiles. Failure: Termination of the ability of a system, structure, or component to perform its required function. Failures may be unannounced and undetected until the next inspection (unannounced failure), or they may be announced and detected by any number of methods at the instance of occurrence (announced failure). Failure Mode: The manner of failure. For Risk-Based Inspection, the failure of concern is loss of containment of pressurized equipment items. Some examples of failure modes are pinhole, crack and rupture. Hazard: A physical condition or a release of a hazardous material that could result from component failure and result in human injury or death, loss or damage, or environmental degradation. The hazard is the source of harm. Components that are used to transport, store, or process a hazardous material can be a source of a hazard. Human error and external events may also create a hazard. Page 6 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Hazard and Operability (HAZOP) Assessment as per OSHA 29 CFR 1910.119 and SAER-5437: A HAZOP assessment is a Process Hazard Analysis (PHA) form of failure mode and failure effect analysis. HAZOP studies, which were originally developed for the process industry, use systematic techniques to identify hazards and operability issues throughout an entire facility. They are particularly useful in identifying latent hazards designed into facilities due to lack of information, or introduced into existing facilities due to changes in process conditions or operating procedures. The basic objectives of the techniques are: 

To systematically review every part of the facility or process to discover how deviations from the intention of the design can occur; and



To decide whether these deviations can lead to hazards or operability issues.

Initial RBI Assessment: The first comprehensive RBI assessment performed on any asset or group of assets (Plant or Unit). In-plant piping: Piping that is inside the boundary limits of the plant and is generally, but not necessarily, designed to ASME B31.3 code except in area(s) set aside for piping within other code or government regulations. Inspection Engineer: For the purpose of this document an Inspection Engineer can refer to Inspector, Sr. Inspector or Field Supervisor that works in the Plant Inspection Unit. Inspection Effectiveness: Is qualitatively evaluated by assigning the inspection methods to one of five descriptive categories ranging from Highly Effective to Ineffective. Inspection Plan: based on risk analysis refers to the output of the planning process of determining what to inspect (which equipment), how to inspect (technique), the extent of inspection (coverage) and when to inspect the equipment. The inspection plan should detail the unmitigated risk related to the current operation. For risks considered unacceptable, the plan should contain the mitigation actions that are recommended to reduce the unmitigated risk to acceptable levels. It is recognized that some risks cannot be adequately managed by inspection alone and other mitigation actions make be required in such circumstances. Inventory Group: Inventory of attached equipment that can realistically contribute fluid mass to a leaking equipment item. Integrity Operating Window: Established limits for process variables that can affect the integrity of the equipment and plant if the process/operating variables deviate from the established limits beyond a predetermined amount of time. Integrity Operating Window may be categorized as Safety IOW, Operational Page 7 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

IOW or Integrity IOW. Also referred to as Plant Integrity Window (PIW)#; Changes in valid PIW's could be used for CMP in addition to RBI. Management of Change: is a procedural system of control supported by appropriate documentation to ensure that safeguards are in place to eliminate the possibility of hazard introduction as a result of changes, other than replacement in kind to equipment, fluid composition, operations, process parameters, control parameters, trip and alarm set points as described in Loss Prevention Department Saudi Aramco Safety Management Guide and API RP 750. In RBI context it is a procedure supported by documentation to ensure that all key parameters, identified and used as a basis for the RBI assessment, are controlled to be within the assessment defined ranges. It also specifies that any change to those parameters requires a review by the appropriate expertise for impact on equipment deterioration or consequences. The review of the MOC shall be performed by a Saudi Aramco employee. All MOC’s shall be reviewed and signed by the RBI facilitator in the inspection unit. Mitigation: Limitation of any negative consequences of a particular event. Mechanical Integrity: the ability of the assets to withstand the design loads for optimum operation and maintenance of the assets at best condition throughout its life cycle. Off-plot Piping: Piping that is outside the boundary limits of the plant and is generally, but not necessarily, designed to ASME B31.4/B31.8 code except in area(s) set aside for piping within other code or government regulations. On-Stream Inspection (OSI): The use of any number of nondestructive testing procedures to establish the suitability of equipment for continued operation. The equipment may, or may not, be in operation while the inspection is performed. Operational Cycle: An operational cycle is defined as the initiation and establishment of new conditions followed by a return to the conditions that prevailed at the beginning of the cycle. Three types of operational cycles are considered: the startup-shutdown cycle, defined as any cycle that has atmospheric temperature and/or pressure as one of its extremes and normal operating conditions as its other extreme; the initiation of, and recovery from, any emergency or upset condition that must be considered in the design; and the normal operating cycle, defined as any cycle between startup and shutdown that is required for the vessel to perform its intended purpose.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Probability (Likelihood): The chance that a given event will occur. The mathematical definition of a probability is “a real number in the scale 0 to 1 attached to a random event.” Probability can be related to a long-run relative frequency of occurrence or to a degree of belief that an event will occur. For a high degree of belief, the probability is near 1. Frequency rather than probability may be used in describing risk. Proponent: The customer who can undertake the assessment or for whom the assessment is being undertaken by another party. QA/QC: The combination of quality assurance, the process or set of processes used to ensure the quality of a product or service, and quality control, the process of validating products and services to specific requirements. (Quality Assurance is process oriented focusing on defect prevention, while quality control is product oriented and focuses on defect identification.) Qualitative Risk Analysis (Assessment): Methods that use engineering judgment and experience as the bases for the analysis of probabilities and consequences of failure. The results of qualitative risk analyses are dependent on the background and expertise of the analysts and the objectives of the analysis. Quantitative Risk Assessment: An assessment that: 

Identifies and delineates the combinations of events that, if they occur, will lead to a severe accident (e.g., major explosion) or any other undesired event.



Estimates the frequency of occurrence for each combination, and



Estimates the consequences.



Estimates the risk of interest, which can be based on production loss, damage to the facility, population, environment or a combination of risk types.

The quantitative risk assessment integrates into a uniform methodology the relevant information about facility design, operating practices, operating history, component reliability, human actions, the physical progression of accidents, and potential environmental and health effects, usually in as realistic a manner as possible. Quantitative risk assessment uses logic models depicting combinations of events that could result in severe accidents and physical models depicting the progression of accidents and the transport of a hazardous material to the environment. The models are evaluated probabilistically to provide both qualitative and quantitative insights about the level of risk and to identify the design site or operational characteristics that are the most important to risk. RASCI: A tool used to define roles and responsibilities during a process.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

RBI Team: A team of people with the requisite skills and background in RBI to conduct an effective assessment. The team is made up of Plant Proponent personnel and/or Service Provider personnel. RBI Facilitator: A member of an RBI assessment team with the responsibility of providing assistance, guidance or supervision to team members and to facilitate the data collection and entry into the RBI software. This shall be a Saudi Aramco proponent employee for in-house RBI assessment and combination of SA employee and Service Provider for contracted RBI assessment. Risk: The combination of the probability of an event and its consequence. Risk Analysis: Systematic use of information to identify sources and to estimate the risk. Risk analysis provides a basis for risk evaluation, risk mitigation and risk acceptance. Information can include historical data, theoretical analysis, informed opinions, and concerns of stakeholders. Risk Assessment: Overall process of risk analysis and risk evaluation, which consists of deciding whether or not the risk is tolerable. Risk Evaluation: Process used to compare the estimated risk against given risk criteria to determine the significance of the risk. Risk evaluation may be used to assist in the acceptance or mitigation decision. Risk-Based Inspection (RBI): A risk assessment and management process that is focused on loss of containment of pressurized equipment in processing facilities, due to material deterioration. These risks are managed primarily through equipment inspection. Risk Management: Coordinated activities to direct and control an organization with regard to risk. Risk management typically includes risk assessment, risk mitigation, risk acceptance, and risk communication. Risk Mitigation: Process of selection and implementation of measures to modify risk. The term risk mitigation is sometimes used for measures themselves. RBI Software Practitioner: An individual who has experience using the RBI software (minimum of two assessments) and the knowledge to perform the analysis required to develop an inspection plan based on the results. Risk Tolerance: A decision to tolerate a risk. Risk acceptance depends on risk criteria. Semi-Quantitative Risk Analysis (Assessment): Refer to API 580.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Source: Thing or activity with a potential for consequence. Source in a safety context is a hazard. Team Leader: Specialist or Engineer assigned to coordinate and manage all activities involved in a RBI assessment. This could be a Saudi Aramco employee or Service Provider. Unmitigated Risk: The risks for which mitigation activities have yet to be performed. 5.2

Abbreviations API AIMS ASME COF CML CMP CSD CUI EIS ES ETC HAZOP HIC ID LOF LPD MOC MPY NDT OSHA OSI PFD PHA POF PRDs PSM PWHT

American Petroleum Institute Asset Integrity Management System American Society of Mechanical Engineers Consequence of Failure Condition Monitoring Location Corrosion Management Program Consulting Services Department (Dhahran) Corrosion under Insulation Equipment Inspection Schedule Engineering Services Estimated Time of Completion Hazard and Operability Assessment Hydrogen Induced Cracking Inspection Department (Dhahran) Likelihood of Failure Loss Prevention Department (Dhahran) Management of Change Mils per Year Nondestructive Testing Occupational Health and Safety Administration On-Stream Inspection Process Flow Diagram Process Hazard Analysis Probability of Failure Pressure relieving Devices Process Safety Management Post-Weld Heat Treatment Page 11 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

P&ID QA/QC QRA RASCI RBI RCM ROI RPO SAER SCC SOHIC SSC SIS TIC UT 6

Process & Instrumentation Diagram Quality Assurance and/or Quality Control Quantitative Risk Assessment Responsible, Accountable, Supports, Consulted, Informed Risk-Based Inspection Reliability Centered Maintenance Return on Investment Release Purchase Order Saudi Aramco Engineering Report Stress Corrosion Cracking Stress Oriented Hydrogen Induced Cracking Sulfide Stress Cracking Safety Instruction Sheet Technical Information Center Ultrasonic Testing

Instructions 6.1

RBI Methodology 6.1.1

The RBI methodology currently approved and implemented is the API RBI from the American Petroleum Institute as described in API RP 580 and API RP 581.

6.1.2

The latest available version of the API RBI software shall be used where applicable to perform assessments. The software custodian within Saudi Aramco is Inspection Department.

6.1.3

Usage of other RBI methodologies and software for quantitative risk assessment is permissible for assets not covered by API-RBI software. These RBI methodologies and software shall be approved by the Engineering Services (ES) RBI team, Inspection Department.

6.1.3

Each facility should prioritize the implementation of RBI for each Unit based on next T&I date and integrity issues associated with operating risk.

6.1.4

Appendix 1 decision tree shall be used to determine if a quantitative RBI assessment is required or only a comprehensive review of the OSI program per 6.11.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

6.2

6.1.5

A fully integrated Risk Based Inspection process should be implemented as shown in Appendix 6. Each Phase has a specific timeline that shall be completed within the allotted time. If the time is exceeded notifications of the delays are sent by ID to the proponent as shown in Appendix 4.

6.1.6

Appendix 2 RASCI chart defines the roles and responsibilities of all participants.

6.1.7

Appendix 3 is the workflow for in-house assessments.

6.1.8

Appendix 4 is the workflow for Service Providers assessments.

Equipment Grouping 6.2.1

Corrosion Loop The corrosion loop shall consist of a drawing and description as defined in this procedure. The drawing shall be developed using a process flow diagram (PFD) or piping and instrumentation diagram (P&ID) in Portable Document Format (PDF) shall be color coded and include information about metallurgy, process conditions and potential damage mechanisms for each system. The description of the corrosion loop shall include a brief summary of the process, limits of the corrosion loop and list of damaged mechanisms per equipment and piping circuit. Information to be included in the corrosion loops description and drawings are addressed further in Appendix 6. Establish corrosion loops for the full unit under assessment. Each loop shall include all main lines and associated piping/branches attached to these main lines.

6.2.2

Piping Piping systems which meet any of the following criteria shall at least require a semi-quantitative risk analysis (comprehensive OSI review) or full RBI assessment where applicable as addressed in Appendix 1: a)

Process piping containing hydrocarbon, toxic or corrosive fluid.

b)

Piping failure that could present a hazard to humans, to the environment, or where such failure could not be repaired without

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

disrupting operation. c)

Piping known to exhibit a high probability of failure, e.g., piping with injection point(s), dead leg(s) or vibrations.

d)

Piping known to be susceptible to Corrosion under Insulation (CUI) and environmental damage such as Stress Corrosion Cracking (SCC) with failure consequences shown in item 2 above.

Commentary Note: Criteria in this paragraph were developed for use in RBI assessments. Piping not meeting the above criteria may not be exempted from being monitored in the OSI program.

6.3

6.4

Inventory Group 6.3.1

A process flow diagram (PFD) or piping and instrumentation diagram (P&ID) in Portable Document Format (PDF) shall be color coded to identify the inventory group and name. The facility Process Engineer shall concur on the inventory group using Appendix 9 Validation Form.

6.3.2

Separate Inventory Groups by highly reliable isolation valves can be actuated remotely e.g., MOVs, ZVs, ESD, etc.

Equipment/Component Items in Plant Facilities 6.4.1

6.4.2

6.5

API RBI assessment shall be applied to all pressure containing equipment (according to the RBI decision tree; Appendix 1) such as: 1) 2)

In-plant piping Pressure vessels (reactors, columns, drums, etc.)

3)

Heat exchangers and fin fans

4)

Tanks

5)

Pressure relieving devices (PRD)

6)

Exchanger tube bundles

All equipment items which are not covered by API RBI but do meet the requirements for RBI decision tree in Appendix 1 should be assessed by RBI methodology approved by ID.

Off-Plot Piping Off-plot piping should be included but the software used in the assessment shall be approved by the Inspection Department before deployment.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

6.6

Utilities Utilities may be included at the discretion of the proponent if there is a specific reliability problem. An example would be a cooling water system with corrosion and fouling problems. An RBI approach could assist in developing the most effective combination of inspection, mitigation, monitoring, and treatment for the entire facility.

6.7

Offshore Facilities Software and methodology other than APIRBI shall be used with prior approval by ID. The assessment shall cover top and subsea steel structures, risers and subsea pipelines.

6.8

Above Ground Atmospheric Storage Tanks Environmental sensitivity shall be determined by the list provided by Saudi Aramco, Environmental Protection Department, Appendix 13. EPD shall be consulted prior to start of assessment, for other areas not listed.

6.9

6.10

PRDs 6.9.1

Overpressure demand cases are critical in PRDs risk assessments. P&CSD shall be consulted on appropriate value.

6.9.2

Fire demand case shall not be used for gas vessels with a liquid level less than 10%.

RBI Documentation 6.10.1 Required Data – Sufficient information and data shall be captured to fully document the RBI assessment including: a)

The level of the assessment as defined in this SAEP.

b)

Team members performing the assessment.

c)

Timeframe over which the assessment is applicable.

d)

The inputs and sources used to determine risk.

e)

Assumptions made during the assessment.

f)

The risk assessment results and inspection plan.

g)

Follow-up mitigation strategy, if applied, to manage risk.

h)

The risk reduction if inspection plan is implemented.

i)

The mitigated risk levels, i.e., residual risk after mitigation is

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

implemented. j)

References to codes or standards that have jurisdiction over extent or frequency of inspection.

6.10.2 Any methodology other than API RBI shall be thoroughly documented indicating the level of assessment performed. 6.10.3 The specific software program and version used to perform the assessment shall be documented. 6.10.4 Risk Based Inspection risk results should be documented as well as the recommendations made for optimized inspection plans. 6.10.5 Projected risk results with implementing the inspection recommendations and without implementing of the inspection recommendations shall be documented for items that require mitigation. 6.10.6 Codes and Standards utilized shall be documented. Refer to Section 4 for a listing of relevant codes and standards. Commentary Note: Since various codes and standards cover the inspection for most pressure equipment, it is important to reference these documents as part of the RBI assessment. This is particularly important where implementation of RBI is proposed to relax either the extent or frequency of inspection.

6.10.7 The final RBI assessment report shall be aligned with latest version of the SA RBI assessment report template provided by ES RBI team 6.10.8 ES RBI team will provide a report number for new initial RBI assessments, to maintain the track of all RBI reports. 6.10.9 Extension of T&I frequency shall be in accordance with SAEP-20. 6.11

Record Keeping 6.11.1 All data relevant to the RBI assessment including RBI software database shall be captured and maintained such that the assessment can be recreated or updated at a later time. The data shall be stored in designated data management system as directed by the Inspection Department. 6.11.2 Assurance that all RBI assessment-related data and reports are properly preserved is the responsibility of the Plant RBI facilitator/Team Leader during the assessment, and the Plant Inspection Unit Supervisor, after the assessment is completed. Page 16 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

6.11.3 Overall responsibility for updating RBI assessments, ensuring implementation of the evergreening process, data storage and management belongs to the proponent Inspection Unit, Supervisor. The evergreening report number will be same as initial assessment report number with a reference indicating evergreening revision iteration. 6.12

Degradation Mechanism The following items shall be documented in the final report: 6.12.1 Identified active and potential damage mechanisms for each corrosion loop shall be based on API RP 571 and/or Saudi Aramco Corrosion Management Program (CMP) Manual SABP-A-033 or other industry documents. 6.12.2 Damage or degradation mechanisms not listed in API RP 571 or CMP shall be identified but no identification number is required. The identification shall include, but not be limited to, the description of damage type, affected materials, critical factors, affected units or equipment, appearance or morphology of damage, prevention / mitigation options, inspection/monitoring, related mechanisms, references and any other description which might be required by the proponent or ID. 6.12.3 Criteria used to judge the severity of each degradation mechanism. 6.12.4 Anticipated failure mode(s) (e.g., leak or rupture). 6.12.5 Key factors used to judge the severity of each failure mode. 6.12.6 Criteria used to evaluate the various consequence categories, including safety, health, environmental and financial. 6.12.7 List the parameters to monitor for risk level control. Certain properties of the process variables have a direct impact on the level of susceptibility of the equipment to damage mechanisms. This information shall be captured on the individual corrosion loop under the name “Susceptible Threshold Values.” 6.12.8 Corrosion loop description shall be aligned with the last template revision provided by ID or CMP Corrosion Control Document.

6.13

Inspection Effectiveness Tables 6.13.1 Relates to the capability of an inspection program in locating and sizing deterioration, and thus for determining deterioration rates for a specific Page 17 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

likely damage mechanism. The inspection technique may be a combination of NDT methods such as visual, ultrasonic, radiographic etc., frequency and coverage/location of inspections. Determination of inspection effectiveness should include equipment type, active and credible damage mechanism(s), rate of deterioration or susceptibility, NDT methods, coverage and frequency and accessibility to expected deterioration or damage areas. 6.13.2 Appendix 10 shall be used to identify the required amount and type of inspections based on the identified damage mechanism. 6.14

6.15

Evergreening RBI Assessments are required: 1)

To maintain and update all RBI programs.

2)

To ensure the most recent inspection, process and maintenance information are included.

3)

After any changes in process conditions, hardware changes, damage mechanisms or corrosion rates, premise changes (per API RP 580 Paragraph 15.2.4) and a change in mitigation strategies.

4)

Immediately after a T&I, operational cycle or when changes occur.

5)

After optimizing the OSI program based on the results of the initial RBI assessment and/or SAEP-1135 requirements.

6)

After Unit changes due to MOC or no longer than a maximum of 3 years. The governing inspection codes, such as API STD 510, API STD 570 and API STD 653 and corporate procedures such as SAEP-20 should be reviewed in this context.

Evergreening process shall include: 1)

Keeping a record for all changes since the initial RBI assessment was completed, that has the potential to affect the RBI results.

2)

Updating of inspection history in the software.

3)

Reviewing of operating variables and inventory groups by proponent Process Engineering.

4)

Reviewing and concurrence of corrosion loops and damage mechanism.

5)

Reviewing and update of assumptions.

6)

Updating the corrosion rate in the software.

7)

Recalculating of the equipment risk and create an inspection plan for mitigation. Page 18 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

8)

Issuing of a final report.

9)

Presenting the results to proponent Management.

10) Completing the Validation Form. 6.16

6.17

Update of RBI Software Database 1)

An update shall be performed to capture OSI updates including inspection of small diameter fittings, chemical injection inspections and dead legs.

2)

The database shall be renamed with a new RBI date in order to track changes from the last formal RBI assessment.

Evergreening report shall include: 1)

Executive Summary including the observations, conclusions and recommendations

2)

Documented assumptions

3)

A list of all changes since completion of the initial RBI assessment

4)

Review of corrosion loops and inventory groups

5)

Review of process parameters

6)

Assessment findings including inspection history review and risk analysis

7)

The results of OSI optimization performed based on the initial RBI assessment results and/or OSI optimization criteria per SAEP-1135

8)

Financial benefit including the OSI optimization and risk reductions

9)

Corrosion loop drawings and descriptions

10) Inventory group drawings 11) Associated piping list 12) Equipment inspection history (new only) 13) Risk summary and inspection plan Commentary Note: The evergreening report shall be aligned with the latest template provided by ES RBI team.

6.18

Comprehensive Review of the OSI Program A comprehensive review of the OSI program shall be performed per SAEP-1135 during RBI assessment, or in lieu of RBI assessment, if directed by Appendix 1 “Decision Tree for Performing RBI”.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

6.19

RBI Team Makeup RBI requires data gathering from many sources, specialized assessment, and then risk management decision-making. Generally, one individual does not have the background or skills to conduct the entire assessment. RBI assessment shall be conducted by a team of people with the required competencies. Some team members may be part-time due to limited input needs. It is also possible that not all the team members described in this SAEP may be required if other team members have the required skill and knowledge of that discipline. 1)

Team Leader 

The Team Leader shall be proposed by the Proponent's Management for in-house assessments and service provider for contracts or RPO assessments. This individual shall be a Sr. Inspection Engineer, Materials/Corrosion Engineer or process engineer.



RBI Contractors’ team leaders shall demonstrate to the ES RBI Team their personnel are suitably qualified and experienced in RBI technology. The qualifications of the RBI personnel shall be documented.



If data is unavailable, the team leader should validate assumptions of the current conditions, as provided by the team members.



Validating data in the RBI software, controlling quality of data input / output, calculating the measures of risk and displaying the results in an inspection plan, and reviewing the final report, is required. Team Leader qualifications: o Demonstrated skills in team leadership and project management o Degree in Engineering and minimum of 5 years’ experience in Oil and Gas industry or 15 years’ experience in the Oil and Gas Industry. o Adequate training in RBI methodology and software navigation, i.e., having actively participated in a minimum of two RBI assessments using the software approved for the assessment. o Experience in NDT disciplines. o Excellent report-writing skills o Excellent presentation skills

2)

RBI Facilitator RBI facilitator should prioritize the implementation of RBI for each Unit based on next T&I date and integrity issues associated with operating risk. Page 20 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Proponent RBI facilitator selection criteria shall be: 

Competencies demonstrated and accepted to ES RBI team leader to run or lead an RBI assessment.



Participation in a minimum of three RBI assessments before qualification.



Any qualified RBI Facilitator who has not performed, participated or coordinated an assessment in a year's time shall require re-qualification from ES RBI team.



All qualified RBI Facilitator shall be orientated to any new version of the software before they will be allowed to perform an assessment using the new version.



Contractors’ RBI facilitator selection criteria shall be: Contractors shall demonstrate to the ES RBI Team that their RBI facilitators are suitably qualified and experienced in RBI technology. The qualifications of the RBI personnel shall be documented in the CVs and references. Contractor personnel must meet the following qualifications: i. Degree in Engineering and minimum of 5 years’ experience in Oil and Gas industry or 15 years’ experience in the Oil and Gas Industry. ii. Detailed training in the RBI methodology/software and participated in at least three RBI assessments two of which involved using the API RBI software.

3)

Sr. Inspection Engineer or Inspection Engineer Sr. Inspector Engineer or Inspection Engineer involved in RBI assessment shall meet one of the following qualifications:

4)



A diploma or degree in a technical discipline.



Minimum of 10 years inspection experience in the Oil and Gas Industry.

Materials and Corrosion Engineer Materials/Corrosion Engineer involved in RBI assessment shall meet two of the following qualifications: 

Have a B.S. Engineering (Chemical, Metallurgical or Mechanical) Degree with 12 years minimum experience in the oil and Gas Industry.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

5)



Have 20 years of experience as a corrosion professional, NACE specialist or equivalent certification with experience in corrosion control in the Oil and Gas Industry.



Demonstrate experience in corrosion risk assessment.

Process Engineer Process Engineer shall meet the following qualifications:

6)



Degree in Chemical Engineering or other suitable Engineering major.



Minimum of 7 years’ experience in the Oil and Gas industry.



Demonstrate experience in corrosion risk assessment.

RBI Software Practitioner RBI Software Practitioner shall meet three of the following qualifications:

7)



Degree in Engineering and minimum of 7 years’ experience in Oil and Gas industry.



Have 15 years’ experience in the Oil and Gas Industry.



Training and job experience using the RBI software in a minimum of two RBI assessments in the last two years.



Demonstrate experience in corrosion risk assessment.

Operation Representative Operations Personnel shall meet the following qualifications:

7



Minimum of seven years in the Oil and Gas industry.



Training in the process Unit under assessment.

8)

Maintenance Engineer

9)

Loss Prevention Engineer

Responsibilities 7.1

ES RBI Team 1)

Assess Plants RBI program per SAEP-308 and SAEP-372 (ID).

2)

Initiate the Inspection Department Manager’s escalation letter to the proponent manager when the ETC of the RBI recommendations overdue.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

7.2

3)

Monitor the implementation of the RBI assessment against the Project Timeline. When the timeline Phases are not completed on the estimated dates, ID/OID/IEU will issue a letter of non-conformance. The non-conformance letter shall be issued progressively to higher level of management per Appendix 5.

4)

Provide guidance for RBI assessment recommendations against the ETC submitted by the operating facility and concurred by ID. When the recommendations are not completed on the estimated dates, ID/OID/IEU could issue a letter of non-conformance. The non-conformance letter shall be issued progressively to higher level of management per Appendix 4.

5)

Validate the assessment per Appendix 11.

Team Leader 1)

Prioritize the implementation of RBI for each Unit based on next T&I date and integrity issues associated with operating risk

2)

Participate in the formation of the team and ensuring that team members have the necessary skills and knowledge.

3)

Prepare a Gantt chart depicting assessment tasks, activities, appropriate durations and assigned resources.

4)

Ensure the assessment is conducted as per the project timeline, according to requirements of this SAEP: a)

Gathered data is accurate.

b)

Damage mechanism and corrosion loops are concurred by a service provider corrosion engineer and/or proponent Materials/Corrosion Specialist or CMP (Team.

c)

Assumptions made are logical, documented and approved by ES RBI Team.

d)

Competent personnel provide required data and/or assumptions.

e)

Check quality of data imported into the RBI software.

f)

Prepare or review all reports (preliminary and final) on the RBI assessment and ensuring the report is distributed to the appropriate personnel and management.

g)

Ensure the validation sheet (Appendix 11) has been completed and signed by all parties upon completion of the assessments.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

5) 7.3

7.4

7.5

Follow-up to ensure that the appropriate risk mitigation actions have been implemented.

RBI Facilitator 1)

Prioritize and schedule the implementation of initial RBI assessment for each Unit based on next T&I date and integrity issues associated with operating risk.

2)

Assemble all data required for the RBI assessment.

3)

Define data required from other team members, verifying through quality checks the validity of data and assumptions.

4)

Import the data into the RBI software and run the calculations.

5)

Analyze the risk results and prepare the final report.

6)

Develop tracking system for implementing RBI recommendations.

7)

All MOC’s shall be reviewed and signed by SA RBI facilitator in the inspection unit.

Sr. Inspection Engineer or Inspection Engineer 1)

Gather equipment data and inspection history included in the assessment. The data should include, but not limited to, OSI report, T&I report, SISs, manufacture record book, piping specification book, MFL report…etc. If any of the data required is not available the Sr. Inspection Engineer or Inspection Engineer, in conjunction with the Materials/Corrosion Engineer, should provide assumptions of the current condition.

2)

Assess effectiveness of past inspections.

3)

Recommend inspections and implement recommendations derived from the RBI assessment.

Materials/Corrosion Engineer 1)

Develop the plants corrosion loops by identifying the active/potential damage mechanisms and their applicability and severity to the equipment and piping, considering the process conditions, environment, metallurgy, age, etc., of the equipment. Refer to Appendix 6 Process Map for development of corrosion loops and Damage mechanisms

2)

Review and validate the outcome of the inspection plan for appropriateness of the inspections in relation to the damage mechanism.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

7.6

7.7

7.8

3)

Provide recommendations on methods of mitigating the likelihood of failure (such as changes in metallurgy, addition of inhibition, addition of coatings/linings, etc.).

4)

Provide operating windows and ranges for the process parameters to be monitored which can affect the potential and severity of damage mechanism in a corrosion loop. These ranges of the parameters shall be controlled through the facility's management of change (MoC) written procedure. Changes that fall outside the range shall trigger an RBI assessment update or review (Evergreening).

Plant Engineer 1)

Provide process parameters such as pressure, temperature, flow stream composition, etc.

2)

Document variations in the process conditions due to normal occurrences (such as start-ups and shutdowns) and abnormal occurrences.

3)

Describe the composition and variability of all the process fluids as well as their toxicity and flammability.

4)

Provide information required for financial assessment such as equipment replacement cost and production losses.

5)

Evaluate and recommend methods of risk mitigation through changes in process conditions.

6)

Participate in the development of the Inventory Groups and sign off concurrence.

RBI Software Practitioner 1)

Input data into the RBI software.

2)

Run the RBI software.

3)

Extract and format the inspection plan from the software.

Operations Personnel 1)

Verify that the facility/equipment is being operated within the parameters set out in the process design.

2)

Provide data on occurrences when the process deviated from the limits of the process condition and for obtaining the number and causes of emergency shutdowns and tripping of equipment.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

7.9

7.10

3)

Assist in the development of the Inventory Groups.

4)

Implement recommendations that pertain to process or equipment modifications.

Proponent Management 1)

Provide sponsorship and resources (personnel and funding) for the RBI assessment.

2)

Make decisions on risk management and/or provide framework and mechanism for others to make these decisions based on the results of the RBI assessment.

3)

Provide the resources for implementing RBI recommendations and risk mitigation decisions.

4)

Ensure that MOC program is in place and effective to ensure validity of RBI results.

5)

Ensure operating limits which affect the RBI assessment results, are added to the Integrity Operating window (IOW) limits/ ranges and controlled.

6)

Serve as RBI Champion.

7)

Appoint the Facility RBI Team Leader.

Loss Prevention Engineer Address all consequence aspects and recommend methods to mitigate the consequence of failures. Participation in the RBI assessment team is at the discretion of the RBI Team Leader, on a part-time basis. Provide data on the financial consequences such as production loss, environmental clean-up costs, equipment replacement costs…etc.

7.11

T&I Engineer Provide data on the T&I cost of the facility/equipment being analyzed and the T&I duration.

21 August 2013 7 July 2015

Revision Summary Major revision. Minor revision to remove the requirement of utilizing Saudi Aramco Engineering Report number (SAER) for the RBI final report.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 1 – Decision Tree for Performing RBI Develop Corrosion Loop

Mechanical and Metallurgical Failure Mechanisms per API 571 Section 4 (Not including corrosion)

Yes

Note 1: This decision tree excludes above ground Storage Tanks (API 650 and 12C).

No

Environment – Assisted Cracking

Yes

Note 2: Excluding any process unit from RBI Program shall be approved by ES RBI Team.

No

HTHA Titantium Hydrating

Yes

No Uniform, localized or high temperature corrosion perform a comprehensive review of the OSI program (SAEP-1135)

Robust

No

Yes

Implement recommendations of the Comprehensive Review

Perform Quantitative RBI

Yes

RBI methodology other than API/ RBI could be required

Page 27 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 2 – RBI RASCI Chart

Department: Procedure: Updated:

Step Phase 1, Task 1 Phase 1, Task 2 Phase 1, Task 3 Phase 1, Task 4 Phase 1, Task 5 Phase 1, Task 5a Phase 1, Task 5b Phase 1, Task 6 Phase 2, Task 1 Phase 2, Task 3 Phase 2, Task 4 Phase 2, Task 5 Phase 2, Task 6 Phase 2, Task 7 Phase 2, Task 8 Phase 2, Task 9 Phase 2, Task 10 Phase 2, Task 11 Phase 3, Task 1 Phase 3, Task 2 Phase 3, Task 3 Phase 4, Task 1 Phase 4, Task 2

R A S C I

Operating Facility Perform RBI

Task Determine if RBI is required using SAEP-343 decision tree Develop RBI team Develop Gantt Chart Kick-off meeting Conduct RBI Workshop Develop Corrosion Loops Concur on the Corrosion loops Develop Inventory Groups Site Orientation Visit Collect required Data Review and Mark Process Flow Diagrams with Process data, Damage Mechanisms and Materials of Construction Information Define Likelihood Interview Questions Define Consequence Data and Interview Questions Populate the RBI Software Conduct Site Interviews and Collect Missing Data Review Collected Data with Likelihood Expert Review Collected Data with Consequence Expert Validate data in import spreadsheet Import Data into the API-RBI Software and update Analyze Data inside the API RBI Software and ID validate the database. ID validate the database Prepare Inspection Plan Present Findings to Proponent (on-site) Prepare Final Report Presentation Meeting with Proponent Management

Performs the Task Accountable for the task being completed Supports Consults prior to activity being performed Informed that the task has been performed

Division Team Software Process Corrosion ID LPD Ops Facilitator Practitioner Inspector Engr Head Leader Engr. Rep Rep Rep C A I C I I I I I I

A R A A A A A S A A

R I R R R R A R R R

S I I S S S S S S S

S I I S S S S A S R

S I I S S S A S S R

S I I S S S S S S R

S I I S I S I I I I

S I I I I S I I I I

S I I S S S I S S I

I

A

R

S

S

S

S

I

I

S

I I I I I I I I

A A A A A A A A

R A R A A A A A

S R S R S S S S

S I S S S S S S

S I S S S S S S

S I S S S S S S

I I I I I S S S

I I I I I I I I

I I I S S I I I

I

A

A

S

S

S

S

R

I

I

I I I I I

A A A A A

A A R R R

S R R S S

S I I S S

S I I S S

S I I S S

S S S S S

I I I I I

I I I I S

Page 28 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities Appendix 3 – RBI Process for In-House Assessment Prioritize the Plants Units to determine the order of performing RBI assessments.

RBI Team collects, sorts, formats, reviews and compiles draft corrosion loop drawings and descriptions and marks up the Inventory Group drawings

RBI Team submits draft corrosion loop drawings and description for CSD or service provider for concurrence

RBI Team submits import spreadsheet to ID for approval

No

Accepted

Yes

RBI Team meets with ID on site to populate the database, create the inspection plan and approve the RBI assessment

Submit Final report with Recommendation ETC for ID concurrence.

Upload all RBI assessment documents to secured shared folder (e.g. e-cabinet, e-way, etc..)

Optimize OSI program as per SAES-A-135 and SAEP-1135

RBI facilitator develop tracking system for implementing RBI recommendations Appendix 5

RBI facilitator implement the recommendations and send status to ID.

Evergreen RBI by making a copy of the old database and rename it using the RBI update date. Implement all recommendations and send status to ID.

Page 29 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities Appendix 4 – RBI Process for Service Providers Prioritize the Plants Units to determine the order of performing assessments.

Service Provider shall provide RBI process timeline to Saudi ARAMCO for concurrence.

Service Provider meets SA RBI team and provides a one to two day introductive workshop (orientation for RBI team of their responsibilities and duties and description of RBI process)

Phase 1 Overdue

Service Provider Collects, Sorts, Formats, Reviews and compiles data and reviews or develops draft Corrosion Loops and description and Inventory Groups

No

Yes

Letter of nonconformance issued by ID Phase 1, 3,4 Phase 2 Sent To 2 weeks 4 weeks Division Head 4 weeks 8 weeks Manager 8 weeks 12 weeks Admin Head

Yes

Phase 2 Overdue

No

Incomplete Data

Yes

No

Service Provider submits Draft Corrosion Loops and Description, Inventory Groups and populated database to SA RBI Facilitator for review.

Contact SA RBI Facilitator

Service Provider, proponent & ES RBI Teams meet on-site to review and validate submitted documents and database.

SA RBI Team Leader provides contact details of Plant Engineer, Corrosion Engineer, Inspector or other applicable person who may be able to assist.

SA RBI Team Leader to review submissions for concurrence. Service Provider submits corrosion loops and description, inventory groups and populated database to SA RBI Facilitator for review. Create and document assumptions for missing data and get concurrence from SA RBI Facilitator.

Concur

No

Yes Service Provider meets on site to perform analysis of the RBI assessment with the proponent RBI Team and ID. Ensures they are in correct final format for inclusion in report.

No

Incomplete Data Yes

Yes

Phase 3 Overdue

No

Results Validated by ES RBI Team

No

Report accepted and validation sheet signed off by ES RBI Team

Yes

Yes

Service Provider establishes or reviews CML’s for optimization per SAES-A-135 and SAEP-1135.

Service Provider gives presentation to the proponent management.

Service Provider submits the draft report and presentation to SA RBI Team Leader & ES RBI Team.

Yes

Phase 4 Overdue

No

No

Service Provider returns all collected data and database when assessment is complete.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 5 – RBI Workflow for Tracking Recommendations SA RBI Facilitator adds Recommendations to Tracking System

RBI Report

RBI Team leader suggests ETC for each Recommendation

ID Concur

No

Yes

RBI Facilitator inputs ETC into Recommendation Tracking System Yes ID Concur?

No

Complete Recommendation(s) per ETC

Recommendation Completed

Update RBI Software Database

Yes

No

Request Extension

Overdue?

No

Yes 1st extension sent by Inspection Supv. 2nd extension sent by Division Head 3rd extension sent by Manager

ID sends out letter of nonconformance based on escalation process

T&I Recommendation Overdue 1 month grace period per year of T&I interval Division head Exceeding grace period Manager

Non-T&I Recommendation 1 month overdue Division head 3 month overdue Manager

Page 31 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities Appendix 6 - Corrosion Loop Development Workflow Start

PFD’s, P&ID’s, Material Balance Drawings & Operating Manuals

Review plant documents for design, feed composition & operating parameters.

Verify corrosive elements in the streams and record expected corrosion mechanisms.

PE & CE

CE & PE

Lab Data / Feed Data

Review and P&ID’s for all injection points, and impingement areas from branch piping, injection nozzles, dead legs, etc.

Piping Instrument Drawings

CE & IE

CE Verify equipment and piping materials.

SIS, Data Sheets

Inspection & Cprrosion Data Reports, Post T&I Reports, Failure Analysis (RCFA) Reports and SAIF.

Review Plant inspection data, history, corrosion monitoring failures / RCFA reports and record all damage mechanism experience.

Review and record any operation parameters beyond design limit and list effect on corrosion.

Refer API 571 for generic damage mechanisms and confirmation to list the applicable damage mechanism. DCS Data, Operating Design & Operating Parameters & Lab Data

API 571

CE & IE

PE & CE

CE & IE

CE & IE List all applicable damage mechanisms in the Unit.

Mark all applicable & identified damage mechanisms on the Unit PFD.

Group all piping and equipment together that have the same damage mechanisms, operating parameters and like material with a color code in a sequential manner as a loop.

CE & IE

CE & IE

SAES-L133

Mark different loops for all applicable and identified damage mechanisms on a PFD.

List is a spreadsheet all the loops by their damage mechanisms, operating parameters, materials.

Key: PE Process Engineer CE Corrosion Engineer IE Inspection Engineer

Complete a corrosion loop description that in a word document that includes a short process description, table including each component with description in the loops, listing the specific damage mechanism, PWHT status, Insulation type, material,

CE & IE

CE & IE CMP

CE & IE

RBI

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Document Responsibility: Inspection Engineering Standards Committee Issue Date: 7 July 2015 Next Planned Update: 21 August 2018

SAEP-343 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 7 - RBI Task List 5% of Project Time

70% of Project Time

10% of Project Time

15% of Project Time

Phase 1: Pre-assessment Preparation

Phase 2: Data Collection

Phase 3: Analysis & Insp Planning

Phase 4: Final Reporting & Presentation Meeting

Task 1: Form RBI Team

Task 1: Gathered Required Data

Task 1: Analyze Data in the API RBI Software

Task 1: Prepare Final Report

Task 2: Develop Gantt Chart

Task 2: Review PFDs & Develop Corrosion Loops & Inventory Groups

Task 2: Prepare Inspection Plan

Task 2: Presentation Meeting with Proponent Management

Task 3: Kick-off Meeting

Task 3: Populate and Validate Data in RBI Import Spreadsheet

Task 3: Perform/develop CML optimization

Task 4: Conduct RBI Workshop (for new members)

Task4: Conduct Site Interviews and Collect Missing Data

Task 4: Present Findings to RBI Team Leader

Task 5: Site Orientation Visit

Task 5: Review Collected Data with RBI Facilitator Task 6: Review Collected Data with RBI Team leader & Facilitator

Task 7: Import, Populate and Validate Data in RBI Software

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 8 - Description of RBI Tasks Phase 1 – Pre-Assessment Preparation Task 1 – Form RBI Team Responsibility for the formation of the team is assigned to the Team Leader. This activity is accomplished by a formal written request to the appropriate Department Managers. These requests should specify the following items: 1)

The nature and objective of the assessment

2)

The location of the assessment

3)

The input and responsibilities required from the engineers/specialists requested to participate in the assessment

4)

The duration of the assessment.

The Team Leader shall also specify the extent of the involvement of the team members requested, i.e., whether it is part-time or full-time and whether any additional involvement is required before and after the assessment, e.g., for report writing, data gathering, etc. Proponent Champion is required to confirm the availability of the RBI team requested (or suitable replacements) for the duration requested, by a formal written memorandum to the Team Leader. Task 2 – Develop Gantt Chart The Team Leader shall compile a Gantt chart showing all assessment activities described in the RBI Assessment Activities Section above. He shall specify the required milestones, the assigned resource(s) and duration. This chart may be compiled using software tools such as Microsoft Project. This document is to be submitted, in the first instance, to the Proponent for approval, then to the team members for information. When the assessment is performed by a Service Provider the schedule shall be submitted to the ID RBI team. Task 3 – Kick-off Meeting The Team Leader will develop and agenda and organize a meeting grouping all members of the RBI Assessment Team. It is the Team Leader's responsibility that all necessary personnel are able to attend. The scribe for the kick-off meeting shall be appointed by the Team Leader. The minutes compiled shall be reviewed by the RBI Assessment Team members for Page 34 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

completeness before submission to the proponent. The meeting agenda should include the following issues: 1)

RBI team, commitment of members, schedule and scope.

2)

Data storage as directed by Inspection Department.

Task 4 – Conduct RBI Workshop (required for new members only) Provide team members with an insight into RBI methodology. Emphasize key features and expected benefits. Define the responsibilities of each team member. Task 5 – Site Orientation Visit The RBI team should be given an orientation to the Unit using the process flow diagram (PFD) then performing a walkthrough of the unit. Phase 2 – Data Collection Task 1 – Gather Required Data The success of an RBI assessment depends strongly on the accuracy of the data and information that is based on. It is the RBI Team's responsibility to clearly define the data needed to analyze the equipment so that the results meet the assessment goals and the proponent expectations. Data required for the assessment can be found in Appendix 7. Where possible, all data, including PFDs, should be made available to the Team Leader in electronic format. Data in electronic format saves time when assembling the RBI database and reduces the chances for data entry errors. Assumptions should be made throughout the assessment and included in the final report. Task 2 – Review and mark PFDs for development of the corrosion loops and inventory groups. Review the PFDs and understand the process system. If necessary, simplify these PFDs to include only primary process piping (See 6.2.1 of this document). Optimize the data gathering for in-plant piping using the following steps: 1)

Establish corrosion loops for each individual system. Each loop shall include all main lines and associated piping/branches attached to these main lines. Page 35 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

2)

From each corrosion loop, select one or more main (representative) line and include it in the RBI assessment as a component. Include lines before and after equipment. a)

The corrosion loop description and drawing shall be developed using the template supplied by ID.

b)

The information required for submittal of concurrence of the corrosion loops shall include the following as a minimum: i)

Corrosion Loop description

ii)

Process stream properties

iii)

Marked up corrosion loop description

iv)

Inspection History

v)

Corrosion loop number defining the relevant damage mechanism using API RP 571 and/or Corrosion Monitoring Program including the process fluid, type of material and cladding, toxic model and toxic percentage, HIC resistant material and if stress relieved.

vi)

Mark the operating temperatures and pressures and materials of construction on the appropriate set of PFDs.

3)

Recommendations/inspection guidelines derived for each main line shall also be applicable to the entire corrosion loop piping (associated piping).

4)

Using the PFD & P&IDs, mark the equipment and lines to be included in the assessment and the isolation devices. Based on this, identify the equipment to be included in each inventory group.

5)

Create two working copies of the PFDs. Each working copy will be titled and used for one of the following set of parameters: a)

Inventory group, representative fluids, phases, and the location and type (A, B or C) of isolation devices per API RP 581.

b)

Throughout the assessment, the RBI Engineers shall keep the redrawn PFDs updated with the latest information, as well as the assumptions written on a separate sheet of paper. The marked up PFDs and P&IDs, and the written assumptions become essential RBI Assessment records. Outdated versions of these assessment records should be discarded. It is noted all assessment records are kept with the facility inspection unit who shall be responsible for safekeeping and adequate filing of all RBI assessment documentation.

Task 3 – Populate and validate data in the RBI import spreadsheet Create the component (equipment and piping) list in the latest version of the import spreadsheet (RBIExport). The purpose of creating the equipment list is to define the Page 36 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

boundaries of the systems included, and the actual equipment items to be analyzed. From the information collected and assembled, fill in the required information for each component in the import spreadsheet (RBIExport). Equipment item issues: 1)

In all cases, the component identities and descriptions should match those marked up on the PFDs and P&IDs. To avoid cluttering the PFDs, the piping designation and description do not have to be marked up on the PFDs.

2)

Use the P&IDs and PFDs and list by process flow.

3)

Note any discrepancies between the PFDs and P&IDs for future clarification.

4)

Be consistent with the Equipment Type used. Remember that Equipment Type assigns the generic failure frequency. The Heat Exchanger channel head is designated as HEXTS (tube side) and the shell side as HEXSS. The length of the channel head shall also include the length of the exchanger shell. FinFans are subdivided into E-XXXX-IH (inlet head), E-XXXX-RH (return header) or E-XXXXOH (other head) and E-XXXX-T (tubes) and modeled as Fin Fan components using the circular diameter worksheet to calculate area. Columns can be divided due to different corrosion loops and Knock Out Drums if the boot is weld overlaid. If the ISS or datasheet does not specify the tmin or corrosion allownace for the tubes use ½ the wall thickness for the Specified tmin and ¼ the wall thickness for the CA.

5)

Valves, flanges and reducers are not included in the assessment. However, they may become important inspection objects in high-risk circuits, especially reducers.

6)

In many cases, there will be inadequate records documenting when a piping segment was replaced. On these situations, agree with the proponent on the best number for years in service, and the best number, date and effectiveness of each inspection to be applied globally for all piping.

7)

Piping coming off the equipment is classed as a part of the piping to which it connects.

8)

Piping runs (including piping off the equipment) are classed as single components for the assessment, provided that the material type is the same. The lengths for piping can be estimated as 50’ for short runs but large diameter piping shall be estimated for their full lengths. Do not create different components if the same line has a reducer, use the diameter that produces the larger volume.

9)

If the thickness changes but the pipe identification and diameter remain the same, you may include only the one with the lowest thickness.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

10) Normally, the final inspection plan must consider all components and yet, there may be occasions when this would make the data assembly process excessively time consuming, making it necessary to make simplifications. An example of this is a P&ID containing many small fuel gas lines; in this case instead of entering each pipe, it is useful to enter a typical pipe for that P&ID or service. 11) Some equipment will be modeled in two or more parts to account for the large differences in process conditions and damage mechanisms found between them. This equipment is then broke down as components. For example, heat exchanger tube and shell side, fin fan tubes, fin fan inlet header, and fin fan outlet header, column top, middle and bottom, etc. Documenting Assumptions: 1)

With the available data, populate all applicable sheets and columns of the import spreadsheet. If data is not available, make assumptions so that the final risk result is on the conservative side. Document these assumptions in a word document as an Appendix in the final report.

2)

The assumptions shall be reviewed and approved by the proponent.

Task 4 – Conduct Site Interviews and Collect Missing Data While at the plant, the following activities must be completed: 1)

Complete the collection of basic data

2)

Meet with plant personnel to collect detailed damage mechanisms, inspection and consequence calculation input data needed. These meetings can be done individually or in-groups depending on the issues that must be resolved. Assignment of roles and duties shall be the responsibility of the Team Leader.

3)

Collect missing data in the import spreadsheet.

4)

Meet with the Operator/Process engineer to confirm the location of block valves for inventory grouping, detection systems, injection points, type of toxic (H2S), % of toxic, mitigation systems, representative fluids and phases, pH, contaminants (H2S, Chlorine, Kp factors, velocities, etc.), temperatures and pressures.

5)

Hold a meeting with the Sr. Inspection Engineer or Inspection Engineer and Corrosion Engineer (together or individually) to review past inspection history, repair/replace history, contaminants, damage mechanisms, and assumptions made.

6)

Review the inspection files and collect the inspection information.

7)

Collect the measured corrosion rates for piping and vessels. Before doing this manually, consult with the proponent to see if this information is available in electronic form. Page 38 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

8)

When reviewing the inspection files, it is important to record the nature of inspection carried out on each piece of equipment. This shall include the type of damage mechanism inspected for, the method of inspection applied, the number of inspections, the coverage and the date of each inspection.

9)

When assigning the inspection category, use the Inspection Effectiveness look up tables found in Appendix 8.

Inspection History Reviews Pitting - It is important to note the concentration (use standardized description of pitting per ASTM G46 on certain vessel or pipe locations, etc.), and depth if these have been recorded. The proponent and the Likelihood expert and/or Corrosion Engineer should be consulted in this regard to determine an applicable corrosion rate and determine if damage should be considered localized or general. Corrosion Allowance Use the design corrosion allowance (CA) per SAES-L-105 for piping and the Safety Instruction Sheet (SIS) for equipment or data sheet values. Measuring Corrosion Rate This is measured in mils per year (MPY). 1 mil = 0.001”. Most condition monitoring location (CML) are only read to two decimal places (10-mil accuracy), i.e., a change in thickness from 0.50” to 0.49” is a 10-mil change in thickness. The corrosion rate is usually derived from SAIF, the Saudi Aramco database. The corrosion engineer together with the materials engineer and inspection engineer shall carefully examine the historical data gathered and decide on the most applicable corrosion rates being experienced by the various plant items. Engineering judgment and historical plant experience shall both play a major role in determining the applicable corrosion rates. Note that the selected rates will have a significant effect on the criticality of the plant items under assessment. If the measured corrosion rate is used it shall be the highest mpy for each CML in that equipment circuit, always taking the worst case between the near and long term corrosion rate (CR). If the highest CML selected has a CR higher than 15% of the average of all the other CR’s in the circuit or the last measured thickness of that specific CML it may be wrong and shall be field verified by Saudi Aramco. Documenting Environmental Cracking Inspections It is important to note the extent of environmental cracking inspection performed, the location and the findings derived. Note that metallurgy, PWHT, and hardness are all key factors in determining the susceptibility of plant equipment to SCC, SSC, HIC and SOHIC. Temperature is a key factor in development of Amine cracking Page 39 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

and guidelines from SAES-L-133 shall be followed. The corrosion and materials engineers shall provide the required input with respect to environmental susceptibility and shall pay due regard to current company standards, guidelines and procedures relevant to these damage mechanisms. Saudi Aramco material standards, procurement and construction procedures mandate specifications to eliminate the occurrence of SSC in wet H2S service. With the expectation these specifications are supplemented with a rigorous QA/QC procedure, carbon steel piping shall not be considered susceptible to this particular damage mechanism. It is noted that H2S is usually quantified in ppm. Note also that 1% (mass or weight) = 10,000 ppm or 0.1%=1000 ppm. PFDs normally provide H2S and other components in moles (lb-mol/hr). To obtain a mole % (volume %), divide the moles/hr of the specific component, e.g., H2S, by the total moles/hr. To obtain a mass or weight % for H2S, use the formula:

Heat Exchanger Data The length of tubing of Finfans for RBI is taken as tube length x # of tubes. The inlet/outlet header box (IH), return header (RH) or other head (OH) size (area) has to be converted to diameter and the length will be the depth of the box. The exchanger channel length is taken as 2 x channel length (on U-1 or SIS) for U-tube exchanger and 2 x the channel head length plus the shell length for straight tube. For plate and frame exchangers, it is advised to only model the nozzles. Task 5 – Review Collected Data with Likelihood Expert The corrosion, inspection and materials engineers shall jointly review the inspection, corrosion rates and damage mechanism data collected from the files and interviews. A decision will also be made by this group to set the import spreadsheet (RBIExport) to measured or estimated corrosion rates. This may reduce the assessment time later in the RBI software. Task 6 – Review Collected Data with Consequence Expert The Consequence Expert shall review any changes to the location of block valves for inventory grouping, detection systems, injection points, type of toxic (H2S), % of toxic, Page 40 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

mitigation systems, representative fluids and phases, pH, contaminants (H2S, Chlorine), Kp factors, velocities, temperatures and pressures. Task 7 – Import/Populate and Validate Data in the RBI software A qualified RBI software practitioner shall review every column in the import spreadsheet and verify the validity and accuracy of the data entered. Any assumptions made are to be updated; if required, sensitivity to final results shall be evaluated. Perform the following validity steps in the import spreadsheet: 1)

Verify that there are no duplicate component names

2)

Verify that all data entered match the pull down menus

3)

Check that all data entered makes sense. Check for unusually large or small operating temperatures, pressures, length, diameter, thickness, etc.

4)

Check that the thickness and diameter of every pipe is in accordance with the piping specifications.

5)

Check for consistency with the Equipment Type used.

6)

Check if the Design Temperature is greater than Operating.

7)

Check if the Design Pressure is greater than Operating.

8)

Run a filter for all items running at 400°F or higher. If Carbon or Low Alloy Steels are used, investigate. Are these refractory lined? Clad? Is the corrosion rate chosen high enough? Is the proponent using the wrong material for these temperatures?

9)

Run a filter for all items showing HIC/SOHIC. Use the Steam Tables and make sure water is present, if not, there should be no HIC/SOHIC present.

10) Run a filter for all items showing no damage mechanisms and make sure you agree with what you see. Is this in accordance with the inspection history and findings? 11) Check that all the information written in the two sets of PFDs matches what was written in the import spreadsheet. 12) Ensure the corrosion loop number (CL-?) is a suffix to the component name. 13) Change the name of the import spreadsheet to RBIExport and move to the Import folder (C:\Apirbi_Installation\import).

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Phase 3 – Analysis and Inspection Planning Task 1 – Analyze Data inside the API RBI Software API RBI software functionality is covered in; API RP 581. The major steps to follow when analyzing data in the RBI software are: 1)

Update the Component Data table for ferritic and hi-alloy steels to meet the requirements of SAES-L-310 for structural steel tmin. If structural tmin is greater than pressure tmin put the thickness in the specified tmin cell in the software after the batch calculation is run.

2)

Use the new consequence modeler when performing the final analysis.

3)

Saudi Aramco Inspection department will define the Area and Damage factor Targets. The Risk Tolerance is variable depending on the facility under assessment.

4)

List equipment by the equipment letter, then the number (example D-101) in the equipment and component fields.

5)

List piping by service letter first (example P-1111-6CS9F) in equipment field and by the diameter (example 18-P-1111-6CS9F) in the component field.

6)

Copy all inspection history by year in the comment section of the software for inspection history.

6)

If any parameters are altered as you review the applicable likelihood supplements and consequence information inside the software, run the batch calculations.

7)

Determine what is driving the high likelihood items. Is it the remaining wall thickness? The age? The material of construction used? The lack of inspection? This information shall be documented for inclusion in the final report.

8)

Determine what is driving the high consequence items. Is it the representative fluid used? Phase? Toxicity? Size of the inventory? This information shall be documented for inclusion in the final report.

9)

If the existing software does not properly model a certain damage mechanism or a critical equipment item that the proponent wishes to address, then these shall be analyzed outside the software. Any methodology used to address these issues shall be adequately referenced and documented in the final report.

10) Inspection Department is required to validate the database. Task 2 – Prepare Inspection Plan There are several ways of mitigating risk effectively using the inspection plan that is provided by the software. The likelihood aspect of risk may be reduced by: Page 42 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

1)

Adding an inspection.

2)

Replacing equipment close to its end of life.

3)

Removing the source of corrosion or damage mechanism.

4)

Repairing the coating or insulation if CUI is a driver.

5)

Improved monitoring, i.e., adding Hydrogen Probes or Key Process Monitoring if SCC is a concern.

6)

Modifications to the operating procedures may reduce the consequence side of risk by:

7)

Reducing the toxic and / or flammable inventory

8)

Adding isolation devices

9)

Improving detection systems

10) Reducing manning 11) Building blast walls or dykes (API RP 752) 12) It is cautioned that any mitigation measures considered for risk reduction shall be reviewed by the relevant experts before implementation. It is noted that, for risk reduction inside the software, an inspection may be required. The type and effectiveness (as defined in API RP 581) of the inspection should be determined using the inspection plan and API RP 571 damage mechanism tables. It is not possible to treat the remainder of the mitigation measures inside the software. Rather, these shall be addressed separately in the final report. 13) Prepare the Inspection Plan. Extensions of equipment should be evaluated on whether or not the risk increases with time and with or without new inspections. 14) Discuss and agree with the proponent the cost savings derived from the RBI Assessment. 15) Prepare the Cost Benefit Analysis of the RBI assessment. 16) Present the Inspection Plan and Cost Benefit Analysis to the proponent. Once the proponent has accepted the Inspection Plan and Cost Benefit Analysis, these should then be incorporated into the final report. 17) The cost savings from an RBI assessment may include the following: a)

Reduction of inspections costs as a result of equipment being removed from upcoming scheduled T&Is.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Task 3

b)

Reduction of maintenance costs as a result of equipment being removed from upcoming scheduled T&Is.

c)

Increased production time or run length as a result of inspecting less equipment (i.e., shorter T&Is).

d)

Use of non-intrusive inspections instead of intrusive ones.

e)

Optimization of the CMLs.

f)

The Cost Benefit Analysis should include the Return on Investment (ROI) calculation for the assessment. The ROI represents the net financial benefit calculated and expressed as a percent annual return on investment.

g)

The cost benefit analysis should include optimization of inspection resources. Determine the cost of condition monitoring locations (CML) and review their number and locations for optimization.

h)

The Cost Benefit Analysis may include a business interruption cost calculated as shown below as an example using crude oil as the feedstock.

CML selection and optimization shall be reviewed and implemented using the criteria listed in SAES-A-135 and SAEP-1135:

Task 4 – Present Findings to Proponent (on-site) Provide the proponent with the findings from the assessment at the conclusion of the assessment. The Team Leader or another team member (assigned by the Team Leader) shall provide a PowerPoint presentation to the proponent. This exercise shall be carried out prior to the departure of the team from site and shall focus on the preliminary findings derived from the assessment. It is important that the proponent senior management attend this meeting. Comments made by management and other attendees shall be documented and considered for future incorporation in the Final Report as appropriate. Phase 4 – Final Reporting and Presentation Meeting Task 1 – Prepare Final Report Preparation of this document shall be the responsibility of the Team Leader or Service Provider Facilitator. This report shall incorporate all comments made during the presentation meeting (Phase 3, Task 3) in addition to any other changes. The report shall have a SAER number that is requested from the Technical Information Center.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

The report shall be submitted to the proponent and RBI team members for review. A copy of the report (SAER) shall be submitted to the Technical Information Center. A copy of the final RBI software files should be archived in the electronic storage area identified by Inspection Department folders. This folder is also divided into multiple sub-folders named after the proponent's facility, e.g., Ras Tanura Refinery, Abqaiq Plants, etc. All correspondence, databases, reports, etc., are to be stored in the respective subfolder. The custodian of this folder shall be the RBI team, Operations Inspection Division, ID who will assign access rights to the relevant RBI team members. The team leader for each assessment is responsible for placing relevant assessment data in the folders. Task 2 – Presentation Meeting with Proponent Management Upon submission of the Final Report (SAER), the Team Leader or Service Provider Facilitator shall convene a presentation meeting at the proponent's offices. Participants of this meeting shall include all team members, proponent management and/or ES management. He shall be responsible for the preparation of this presentation. He shall enlist the assistance of selected team members to compile this document and ensure all assessment items are highlighted. It is important that any economic benefits derived from the assessment are duly emphasized. This presentation meeting should take place no later than one week following delivery of the Final Report (SAER).

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 9 - Sources of Site Specific Data and Information Information for RBI can be found in many places within a facility. It is important to stress that the preciseness of the data should match the sophistication of the RBI method used. The individual or team must understand the sensitivity of the data needed for the program before gathering any data. Specific potential sources of information include and are not limited to: 1.

Design and Construction Records / Drawings a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s)

2.

Inspection Records a) b) c)

3.

Safety Instruction Sheets (SIS) P&IDs, PFDs, etc. Piping Isometric Drawings Engineering Specification Sheets Materials of Construction Records Construction QA/QC Records Codes and Standards Used (ASME SEC VIII, NB-23, ASME B31.3, etc.) Protective Instrument Systems Leak Detection and Monitoring Isolation Systems Inventory Emergency Depressurizing and Relief Systems Safety Systems Fire-Proofing and Fire Fighting Systems Layout Line Designation Tables Piping specification drawings Corrosion coupons Corrosion Allowance – SAES-L-105

Equipment Inspection Schedules (EISs) Inspection Histories (OSI data, T&I reports, OSI reports, worksheets) Repairs and Alterations

Process Data a)

Fluid composition analysis including contaminants or trace components Page 46 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

b) c) d) e) f) g) h) i) j)

Process flow diagrams Distributed control system data Operating Instruction Manuals (OIM) Emergency procedures Operating logs and process records PSM, PHA, RCM and QRA data or reports Process description Production loss cost Number of personnel in the unit per day (24 hr avg)

4.

Management of Change (MOC) records

5.

Off Site data and information - if consequence may affect off site areas

6.

Failure Data

7.

a)

Generic failure frequency data. This data may have a significant effect on likelihood of failure where it is used as a basis for calculation. In-house generic failure frequency data may be developed and used.

b) c) d) e)

Industry specific failure data Plant and equipment specific failure data Reliability and condition monitoring records Company incident records

Site Conditions a) b)

8.

Equipment Replacement Costs a) b) c)

9.

Climate/Weather records Seismic activity records

Project cost reports Industry databases T&I costs, maintenance costs

Hazards Data a) b) c) d) e)

PSM studies PHA studies QRA studies Other site-specific risk or hazard studies HAZOP

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 10 – Inspection Effectiveness Tables Table 10.1 – Guidelines for Assigning Inspection Effectiveness – General Thinning Inspection Category

Inspection Effectiveness Category

A

Highly Effective

B

Usually Effective

C

Fairly Effective

D

Poorly Effective

E

Ineffective

Intrusive Inspection Example

Non-intrusive Inspection 1-6 Example

1-6

For the total surface area: 100% visual examination with random UTT measurements of suspect areas, For the total surface area: >50% visual examination with random UTT measurements of suspect areas, For the total surface area: >25% visual examination with random UTT measurements of suspect areas, Or 100% hydrostatic or pneumatic test 6. For the total surface area: 25% UTT or RT of CML’s. Profile radiography made also be performed at selected locations.

>10% UTT or RT of CML’s. Profile radiography made also be performed at selected locations. 40% MFL and Visual Inspection of all accessible tubes. OR >25% IRIS Testing with Visual Inspection “B” Effectiveness- 20-39% MFL and Visual Inspection. OR >15-25% IRIS Testing with Visual Inspection. “C” Effectiveness- 10-19% MFL and Visual Inspection. OR 5-15% IRIS Testing with Visual Inspection. “D” Effectiveness- 75% coverage of the CML’s using manual UTSW, AUT or profile radiography.

For the total area: >50% visual examination AND 100% follow-up at locally thinned areas.

For the total Suspect area: >50% coverage of the CML’s using manual UTSW, AUT or profile radiography.

Fairly Effective

Or 100% hydrostatic or pneumatic test 6.

D

E

Poorly Effective

Ineffective

For the total area: >20% visual examination AND 100% follow-up at locally thinned areas. No inspection, less than above recommendations or ineffective technique used.

For the total Suspect area: >20% coverage of the CML’s using manual UTSW, AUT or profile radiography. For the total Suspect area: 40% MFL and Visual Inspection of all accessible tubes. OR >25% IRIS Testing with Visual Inspection “B” Effectiveness- 20-39% MFL and Visual Inspection. OR >15-25% IRIS Testing with Visual Inspection. “C” Effectiveness- 10-19% MFL and Visual Inspection. OR 5-15% IRIS Testing with Visual Inspection. “D” Effectiveness- 50%.

9.

Any area not subject to visual inspection shall be inspected using non-intrusive inspection methods.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.3 – Guidelines for Assigning Inspection Effectiveness Corrosion Resistant Liner-Non-Metallic Inspection Category

A

B

C

Inspection Effectiveness Category

Intrusive Inspection Example1

For the total surface area: 100% Visual inspection and 20% PT of the welds. AND Highly Effective 100% Holiday test AND 100% UT or magnetic tester for disbonding for bonded liners.

Usually Effective

Fairly Effective

D

Poorly Effective

E

Ineffective

Non-intrusive Inspection Example1 No inspection techniques yet available.

For the total surface area: >75% Visual inspection < 20% PT of welds. AND >75% Holiday test AND >75% UT or magnetic tester for disbonding for bonded liners.

For the total surface area: >95% coverage of the CML’s using advanced or manual UTSW scanning.

For the total surface area: >35% Visual inspection and 35% Holiday test AND >35% UT or magnetic tester for disbonding for bonded liners. For the total surface area: >4% Visual inspection 5% Holiday test AND >5% UT or magnetic tester for disbonding for bonded liners.

For the total surface area: >67% coverage of the CML’s using advanced or manual UTSW scanning.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

For the total surface area: >34% coverage of the CML’s using advanced or manual UTSW scanning.

Assumption: 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.4 – Guidelines for Assigning Inspection Effectiveness – Tank Bottoms Inspection Category

Inspection Effectiveness Category

Soil Side a. b.

A

Highly Effective

c.

a.

B

Usually Effective

C

D

Fairly Effective

MFL Floor scan >90% & UT follow-up Include welds if warranted from the results on the plate scanning Manual UTSW scan of the critical zone

a. b. c. d. e.

MFL Floor scan >50% & UTSW follow-up

a. Brush blast if required b. Effective supplementary light c. Visual 100% (API STD 653) d. Pit depth gauge Coating or Liner: a. Holiday test >75% b. Adhesion test c. Scrape test

OR b. EVA or other statistical method with Floor scan follow-up if warranted by the result

a.

c. d. e.

MFL Floor scan >5% plates; supplement with scanning near Shell & UTSW follow-up; Scan circle and X pattern Progressively increase if damage found during scanning Helium/Argon test Hammer test Cut coupons

a. b.

Spot UTT Flood test

b.

Product Side

Poorly Effective

Commercial blast if required Effective supplementary light Visual 100% (API STD 653) Pit depth gauge 100% vacuum box testing of suspect welded joints Coating or Liner: a. Holiday test 100% b. Adhesion test c. Scrape test

a. Brush blast if required b. Effective supplementary light c. Visual 100% d. Pit depth gauge Coating or Liner: a. Holiday test >50% b. Adhesion test c. Scrape test a. Brush blast if required b. Effective supplementary light c. Visual >25% Coating or Liner: 

E

Ineffective

None

Holiday test 75% WFMPT or ACFM of welds with manual UTSW follow-up of relevant indications.

For the total weld area: >75% AUT or manual UTSW scanning.

For selected welds: >50 WFMPT or ACFM of welds with manual UTSW follow-up of all relevant indications.

For selected welds: >67% AUT or manual UTSW scanning OR AE testing with 100% follow-up of relevant indications.

For selected welds: >25% WFMPT or ACFM of welds with manual UTSW follow-up of all relevant indications.

For selected welds: >34% AUT or manual UTSW scanning OR 67% radiographic testing.

For selected welds: >5% WFMPT or ACFM of welds with manual UTSW follow-up of all relevant indications or

For selected welds: >5-% AUT or manual UTSW scanning OR >34% radiographic testing.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Usually Effective

Fairly Effective

D

Poorly Effective

E

Ineffective

Non-intrusive Inspection Example1-8

Assumptions; 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

2.

Cold bends may need inspection also for Caustic Cracking

3.

Selected weld areas identified by knowledgeable individual

4.

UTSW – Ultrasonic testing shear wave

5.

WFMPT – wet florescent magnetic particle testing as per SAEP-325. WFMPT shall be used as the initial Intrusive inspection technique for Caustic Cracking. If no cracking is detected, then ACFM may be used in lieu of WFMPT for future Caustic Cracking inspection. If cracking is detected by WFMPT, then follow-up inspection must be the same technique. Non-PWHT equipment and equipment subject to frequent steam-out requires WFMPT.

6.

ACFM - Alternating Current Field Measurement. Can be used if equipment has already been WFMPT tested AND provided no history of cracking.

7.

AUT – Advanced ultrasonic testing; Approved Advanced UT techniques are listed in SAEP-1140, paragraph 5.1.3.2

8.

RT inspection can be used in lieu of UTSW for piping less than or equal to 3 NPS.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.6 – Guidelines for Assigning Inspection Effectiveness – Amine Cracking Inspection Category

A

B

C

Inspection Effectiveness Category

Intrusive Inspection Example1-6

Non-intrusive Inspection Example1-6 For the total weld area: >75% AUT or manual UTSW scanning.

Highly Effective

For the total weld area: >75% WFMPT or ACFM of welds with manual UTSW followup of relevant indications. For selected welds: >50% WFMPT or ACFM of welds with manual UTSW followup of all relevant indications.

For selected welds: >67% AUT or manual UTSW scanning OR AE testing with 100% follow-up of relevant indications.

For selected welds: >25% WFMPT or ACFM of welds with manual UTSW followup of all relevant indications.

For selected welds: >34% AUT or manual UTSW scanning OR >67% radiographic testing.

For selected welds: >5% WFMPT or ACFM of welds with manual UTSW follow-up of all relevant indications.

For selected welds: >5% AUT or manual UTSW scanning OR >34% radiographic testing.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Usually Effective

Fairly Effective

D

Poorly Effective

E

Ineffective

Assumptions: 1. Inspection quality is high and all NDT is performed in accordance with approved procedures. 2.

Selected weld areas identified by knowledgeable individual

3.

UTSW – Ultrasonic testing shear wave

4.

WFMPT – wet florescent magnetic particle testing as per SAEP-325. WFMPT shall be used as the initial Intrusive inspection technique for Caustic Cracking. If no cracking is detected, then ACFM may be used in lieu of WFMPT for future Caustic Cracking inspection. If cracking is detected by WFMPT, then follow-up inspection must be the same technique. Non-PWHT equipment and equipment subject to frequent steam-out requires WFMPT.

5.

ACFM - Alternating Current Field Measurement. Can be used if equipment has already been WFMPT tested AND provided no history of cracking.

6.

AUT – Advanced ultrasonic testing; Approved Advanced UT techniques are listed in SAEP-1140, paragraph 5.1.3.2

7.

RT inspection can be used in lieu of UTSW for piping less than or equal to 3 NPS.

Page 54 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.7 – Guidelines for Assigning Inspection Effectiveness – Sulfide Stress Cracking Inspection Category

A

Inspection Effectiveness Category

Highly Effective

Intrusive Inspection Example1-7 For the total surface area: >75% WFMPT or FPT or ACFM of welds with UTSW follow-up of relevant indications.

Non-intrusive Inspection Example1-7 For the total surface area: >75% AUT or manual UTSW scanning.

Perform random hardness testing.

B

Usually Effective

For selected areas: >50% WFMPT or FPT or ACFM with UTSW follow-up of all relevant indications. Perform random hardness testing.

C

Fairly Effective

For selected areas: >25% WFMPT or FPT or ACFM of welds with UTSW follow-up of all relevant indications. Perform random hardness testing.

D

Poorly Effective

E

Ineffective

For selected areas: >67% AUT or manual UTSW scanning OR AE testing with 100% follow-up of relevant indications. For selected areas: >34% AUT or manual UTSW scanning OR >67% radiographic testing.

For selected areas: >5% WFMPT or FPT or ACFM of welds with manual UTSW follow-up of all relevant indications. Perform random hardness testing.

For selected areas: >5% AUT or manual UTSW scanning OR >34% radiographic testing.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Assumptions: 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

2.

Selected weld areas identified by knowledgeable individual

3.

UTSW – Ultrasonic testing shear wave

4.

WFMPT – wet florescent magnetic particle testing as per SAEP-325. Initial testing for “SSC Intrusive inspection” shall be WFMT.

5.

FPT – Florescent penetrant testing

6.

ACFM - Alternating Current Field Measurement

7.

AUT – Advanced ultrasonic testing; Approved Advanced UT techniques are listed in SAEP-1140,

Page 55 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.8 – Guidelines for Assigning Inspection Effectiveness – HIC/SOHIC-H2S Cracking Inspection Category

A

B

Inspection Effectiveness Category

Intrusive Inspection Example1-6

Highly Effective

SOHIC: For the weld and HAZ: >50% manual UTSW and follow up indications with TOFD or other acceptable AUT technique. HIC:100% Visual of total surface area AND random UTSW of the base metal, followed up using AUT for suspect areas.

Usually Effective

SOHIC: For the weld and HAZ: >25% manual UTSW and follow up indications with TOFD or other acceptable AUT technique HIC:100% Visual of total surface area AND random UTSW of the base metal, followed up using AUT for suspect areas.

C

Fairly Effective

D

Poorly Effective

E

Ineffective

SOHIC: For the weld and HAZ: >5% manual shear wave and follow up indications with TOFD or other acceptable AUT technique. HIC: 100% Visual of total surface area AND random UTSW of the base metal, followed up using AUT for suspect areas. SOHIC: For the weld and HAZ: 75% manual UTSW and follow up indications with TOFD or other acceptable AUT technique. HIC: Three 1 ft2 areas manual UTSW of the base metal on equipment each plate and the heads and on piping selected locations, All suspect areas are to be followed up using AUT. SOHIC: For the weld and HAZ: >50% manual UTSW and follow up indications with TOFD or other acceptable AUT technique HIC: Two ½ ft2 areas manual UTSW of the base metal on equipment each plate and the heads and on piping selected locations, All suspect areas are to be followed up using AUT SOHIC: For the weld and HAZ: >25% manual shear wave and follow up indications with TOFD or other acceptable AUT technique HIC: One 1 ft2 areas manual UTSW of the base metal on equipment each plate and the heads and on piping selected locations, All suspect areas are to be followed up using AUT SOHIC: For the weld and HAZ: >5% manual shear wave and follow up indications with TOFD or other acceptable AUT technique. HIC: One ½ ft2 areas manual UTSW of the base metal on equipment each plate and the heads and on piping selected locations, All suspect areas are to be followed up using AUT No inspection or ineffective inspection technique used

Assumptions: 1. Inspection quality is high and all NDT is performed in accordance with approved procedures. 2. Inspection Area; Welds and plates that are susceptible to the damage mechanism. 3. UTSW – Ultrasonic testing shear wave. 4. TOFD – Time of Flight Diffraction 5. AUT - Advanced ultrasonic testing; Approved Advanced UT techniques are listed in SAEP-1140, 6. HAZ – Heat affective zone

Page 56 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.9 – Guidelines for Assigning Inspection Effectiveness – Carbonate Cracking Inspection Category

A

B

C

Inspection Effectiveness Category

Highly Effective

Usually Effective

Fairly Effective

D

Poorly Effective

E

Ineffective

Intrusive Inspection Example1-6

Non-intrusive Inspection Example1-6

For the total weld area: >75% WFMPT or ACFM with manual UTSW follow-up of relevant indications.

For the total weld area: >75% AUT or manual UTSW scanning.

For selected welds: >50% WFMPT or ACFM with manual UTSW follow-up of all relevant indications.

For selected welds: >67% AUT or manual UTSW scanning OR AE testing with 100% follow-up of relevant indications.

For selected welds: >25% WFMPT or ACFM with manual UTSW follow-up of all relevant indications.

For selected welds: >34% AUT or manual UTSW scanning OR >67% radiographic testing.

For selected welds: >5% WFMPT or ACFM with manual UTSW follow-up of all relevant indications or

For selected welds: >5% AUT or manual UTSW scanning OR >34% radiographic testing.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Assumptions; 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

2.

Selected weld areas identified by knowledgeable individual

3.

UTSW – Ultrasonic testing shear wave.

4.

WFMPT – wet florescent magnetic particle testing as per SAEP-325.

5.

ACFM - Alternating Current Field Measurement

AUT – Advanced ultrasonic testing; Approved Advanced UT techniques are listed in SAEP-1140.

Page 57 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.10 – Guidelines for Assigning Inspection Effectiveness – PTA Cracking Inspection Category

A

B

C

Inspection Effectiveness Category

Highly Effective

Usually Effective

Fairly Effective

D

Poorly Effective

E

Ineffective

Intrusive Inspection Example1-4

Non-intrusive Inspection Example1-4

For the total surface area: 100% Visual inspection and >95% dye penetrant or eddy current test with manual UTSW follow-up of relevant indications.

No inspection techniques yet available meet A requirements.

For selected areas: 100% Visual inspection and >67% dye penetrant or eddy current testing with manual UTSW follow-up of all relevant indications.

For selected areas: >75% AUT or manual UTSW scanning OR AE testing with 100% follow-up of relevant indications.

For selected areas: 100% Visual inspection and >34% dye penetrant or eddy current testing with manual UTSW follow-up of all relevant indications.

For selected areas: >50% AUT or manual UTSW scanning OR >67% radiographic testing.

For selected areas: 100% Visual inspection and >5% dye penetrant or eddy current testing with manual UTSW follow-up of all relevant indications

For selected areas: >25% AUT or manual UTSW scanning OR >34% radiographic testing.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Assumptions: 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

2.

Selected weld areas identified by knowledgeable individual

3.

UTSW – Ultrasonic testing shear wave.

4.

AUT – Advanced ultrasonic testing; Approved Advanced UT techniques are listed in SAEP-1140, paragraph 5.1.3.2

Page 58 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.11 – Guidelines for Assigning Inspection Effectiveness – ClSCC Inspection Category

A

B

C

Inspection Effectiveness Category

Intrusive Inspection Example1-5

Non-intrusive Inspection Example1-5

Highly Effective

For the total surface area: No inspection techniques yet available 100% Visual inspection and meet A requirements. >75% Dye penetrant or eddy current test with manual UTSW follow-up of relevant indications.

Usually Effective

For selected areas: For selected areas: >75% manual UTSW scanning and 100% Visual inspection and AUT >50% dye penetrant or eddy OR current testing with manual AE testing with 100% follow-up of UTSW follow-up of all relevant relevant indications. indications.

Fairly Effective

D

Poorly Effective

E

Ineffective

For selected areas: For selected areas: >67% AUT or manual UTSW 100% Visual inspection and scanning >25% dye penetrant or eddy OR current testing with manual >67-100% radiographic testing. UTSW follow-up of all relevant indications. For selected areas: For selected areas: >25% AUT or manual UTSW 100% Visual inspection and scanning >5% dye penetrant or eddy OR current testing with manual >25% radiographic testing. UTSW follow-up of all relevant indications No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Assumptions: 1.

Areas selected by individual knowledgeable in mechanism of attack.

2.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

3.

UTSW – Ultrasonic testing shear wave.

4.

AE – Acoustic Emissions

5.

AUT – Advanced ultrasonic testing; approved Advanced UT techniques are listed in SAEP-1140, paragraph 5.1.3.2

Page 59 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.12 – Guidelines for Assigning Inspection Effectiveness – HSC-HF Inspection Category

A

B

C

Inspection Effectiveness Category

Intrusive Inspection Example1-7

Non-intrusive Inspection Example1-7

Highly Effective

For the total weld area: For the total weld area: >75% AUT or manual ultrasonic >75% WFMPT or ACFM with scanning. manual UTSW follow-up of relevant indications.

Usually Effective

For selected welds: For selected welds: >67% AUT or manual ultrasonic >50% WFMPT or ACFM with scanning manual UTSW follow-up of all OR relevant indications. AE testing with 100% follow-up of relevant indications.

Fairly Effective

For selected welds: For selected welds: >34% AUT or manual ultrasonic >25% WFMPT or ACFM with scanning manual UTSW follow-up of all OR relevant indications. >67% radiographic testing.

D

Poorly Effective

E

Ineffective

For selected welds: >5% WFMPT or ACFM with manual UTSW follow-up of all relevant indications.

For selected welds: >5% AUT or manual ultrasonic scanning OR >34% radiographic testing.

No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Assumptions: 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

2.

Selected weld areas identified by knowledgeable individual

3.

UTSW – Ultrasonic testing shear wave.

4.

WFMPT – wet florescent magnetic particle testing as per SAEP-325.

5.

ACFM - Alternating Current Field Measurement.

6.

AE – Acoustic Emissions

7.

AUT – Advanced ultrasonic testing; approved Advanced UT techniques are listed in SAEP-1140, paragraph 5.1.3.2

Page 60 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.13 – Guidelines for Assigning Inspection Effectiveness – HIC/SOHIC-HF Inspection Category

Inspection Effectiveness Category

A

Highly Effective

B

Usually Effective

C

Fairly Effective

D

Poorly Effective

E

Ineffective

Intrusive Inspection Example1-6

Non-intrusive Inspection Example1-6

SOHIC: For the weld and HAZ: >50% manual shear wave and follow up indications with TOFD or other acceptable AUT technique. WFMPT >50% of weld seams. HIC:100% Visual of total surface area AND random manual UTSW of the base metal with indications followed up on using AUT. SOHIC: For the weld and HAZ: >25% manual shear wave and follow up indications with TOFD or other acceptable AUT technique. WFMPT >20 to 49% of weld seams. HIC:100% Visual of total surface area AND random manual UTSW with indications followed up on using AUT. SOHIC: For the weld and HAZ: >5% manual shear wave and follow up indications with TOFD or other acceptable AUT technique. WFMPT 25% manual shear wave and follow up indications with TOFD or other acceptable AUT technique HIC: One 1 ft2 areas manual UTSW of the base metal on each piping circuit or equipment and indications followed up with AUT. SOHIC: For the weld and HAZ: >5% manual shear wave and follow up indications with TOFD or other acceptable AUT technique. HIC: One ½ ft2 areas manual UTSW of the base on each piping circuit or equipment and indications followed up with AUT. No inspection or ineffective inspection technique used

No inspection or ineffective inspection technique used

Assumptions: 1. Inspection quality is high and all NDT is performed in accordance with approved procedures. 2.

Inspection Area - welds and plates that are susceptible to the damage mechanism.

3.

UTSW – Ultrasonic testing shear wave WFMPT – wet florescent magnetic particle testing as per SAEP-325.

4.

TOFD – Time of Flight Diffraction

5.

AUT – Advanced ultrasonic testing; approved Advanced UT techniques are listed in SAEP-1140, paragraph 5.1.3.2

6.

HAZ – Heat affective zone

Page 61 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.14 – Guidelines for Assigning Inspection Effectiveness – External Corrosion Inspection Category

Inspection Effectiveness Category

Inspection1

A

Highly Effective

Visual inspection of >95% of the exposed surface area with follow-up by UT, RT or pit gauge as required.

B

Usually Effective

Visual inspection of >60% of the exposed surface area with follow-up by UT, RT or pit gauge as required.

C

Fairly Effective

Visual inspection of >30% of the exposed surface area with follow-up by UT, RT or pit gauge as required.

D

Poorly Effective

Visual inspection of >5% of the exposed surface area with follow-up by UT, RT or pit gauge as required.

E

Ineffective

Visual inspection of 51% of suspect areas AND Follow-up of corroded areas with 100% visual inspection of the exposed surface area with UTT, RT or pit gauge For the total surface area: 100% external visual inspection prior to removal of insulation AND Remove >24% of suspect areas AND Follow-up of corroded areas with 100% visual inspection of the exposed surface area with UT, RT or pit gauge For the total surface area: 100% external visual inspection prior to removal of insulation AND Remove >5% of total surface area of insulation including suspect areas AND Follow-up of corroded areas with 100% visual inspection of the exposed surface area with UTT, RT or pit gauge

For the total surface area: 100% external visual inspection AND Follow-up with profile or real time radiography of >66% of suspect areas AND Follow-up of corroded areas with 100% visual inspection of the exposed surface with UTT, RT or pit gauge. For the total surface area: 100% external visual inspection AND Follow-up with profile or real time radiography of >34% of suspect areas AND Follow-up of corroded areas with 100% visual inspection of the exposed surface with UT, RT or pit gauge For the total surface area: 100% external visual inspection AND Follow-up with profile or real time radiography of >5% of total surface area of insulation including suspect areas AND Follow-up of corroded areas with 100% visual inspection of the exposed surface with UTT, RT or pit gauge. No inspection or ineffective inspection technique used

For the total surface area: 100% external visual inspection prior to removal of insulation AND 30% dye penetrant or eddy current testing with manual UTSW followup of all relevant indications.

No inspection techniques available meet requirements

yet

D

Poorly Effective

For the suspected area: 100% external visual inspection prior to removal of insulation AND >5% dye penetrant or eddy current testing with manual UTSW followup of all relevant indications

E

Ineffective

Less than “D” effectiveness or no inspection or ineffective inspection technique used

No inspection techniques yet available meet requirements

A

Highly Effective

AND >100% dye penetrant or eddy current test with manual UTSW follow-up of relevant indications. For the suspected area: 100% external visual inspection prior to removal of insulation

B

C

Usually Effective

AND >60% dye penetrant or eddy current testing with manual UTSW followup of all relevant indications.

Assumption: 1.

Inspection quality is high and all NDT is performed in accordance with approved procedures.

Page 66 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Table 10.18 - Guidelines for Assigning Inspection Effectiveness – HTHA Inspection Category

Inspection Effectiveness Category

A

Highly Effective

Inspection1-9 Inspection techniques for HTHA are not available to qualify for a category A inspection. Inspection of susceptible areas with the following techniques: AUBT for the base metal or in-situ metallography

B

Usually Effective

For Equipment: Minimum one location of (24”x24”) AUBT scanning for each component (Shell and Heads). For Piping: Two locations of (12”x12”) per 50 ft of piping. ABSA, High Frequency UTSW or TOFD techniques for the weld and heat affected zone, Inspection of susceptible areas with the following techniques: AUBT for the base metal or in-situ metallography

C

Fairly Effective

For Equipment: Minimum one location of (12”x12”) AUBT scanning for each component (Shell and Heads). For Piping: One location of (12”x12”) per 50ft of piping. ABSA, High Frequency UTSW or TOFD techniques for the weld and heat affected zone, Inspection of susceptible areas with the following techniques:

D

Poorly Effective

E

Ineffective

AUBT for the base metal or in-situ metallography For Equipment: One location of (12”x12”) AUBT scanning. For Piping: One location of (12”x12”) per 100 ft of piping. ABSA, High Frequency UTSW or TOFD techniques for the weld and heat affected zone, Or Inspect less 75% WFMPT or FPT of susceptible areas. No inspection or ineffective inspection technique used

Assumptions: 1. TOFD – Time of Flight Diffraction; metallography or sampling can be used to confirm suspected indications. 2. Suspected Areas include all surfaces exposed to the HTHA environment, but corrosion or materials engineers shall determine the most susceptible areas for monitoring 3. Selected areas are determined by individuals experienced in HTHA. 4. Inspection quality is high and all NDT is performed in accordance with approved procedures. 5. AUBT - Advanced Ultrasonic Backscatter Technique combined with spectrum analysis and velocity ratio. 6. ABSA - Angle-beam Spectrum Analysis 7. WFMPT – Wet Florescent Magnetic Particle Testing 8. FPT – Florescent Penetrant Testing 9. In-Situ Metallography- Samples shall be taken on the process side and should include the welds, HAZ and base metal.

Page 67 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 11 - RBI Validation Form RBI VALIDATION FORM

Complete this form for every RBI initial and evergreen assessment

Saudi ARAMCO XXXX (6/2011)

(Please read instructions printed on next page.) Unit Name Number:

Plant Name: Saudi ARAMCO

Name:

Badge #:

Telephone:

email:

RBI Facilitator

Name:

Company:

Corrosion Loops

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

Name:

Signature:

Date:

Badge #:

RBI Team Leader

Developed by: Corrosion Loops Concurrence by CSD/CMP Group

Inventory Groups Concurrence by Plt. Engr

Environmental Sensitivity Concurrence by EPD(for AST)

Assumptions Approved by SA Team Leader

Database Validation Approved by ID RBI Team

Inspection Plan Concurrence by ID RBI Team

RBI Assessment Approved by ID RBI Team

Last T&I Date _________ Current EIS Interval _______ EIS Deviation/Extension Proposed Yes ___ No___

Next T&I Date ________

Proposed T&I date ________

Comments:

Submit this form with all EIS deviation or revisions.

Page 68 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 12 - RBI Validation Form Instructions

1. Complete this form every time an RBI assessment has been performed (both initial and evergreen). 2. This form must accompany all requests for EIS deviation or revision application. 3. The RBI Team Leader is someone from the Proponent and is the single point contact for the assessment. 4. The RBI Facilitator may be a Saudi Aramcon or Service Provider, depending on who conducted the assessment. 5. After the Corrosion Loops (CLs) are developed by the Proponent or Service Provider (SP) they require third party concurrence for both initial and evergreening. If the SP develops the CLs the Proponent shall concur. If the Proponent develops the CL a Service Provider or CSD/CMP Group shall concur. Commentary Note: Future RBI assessments shall be conducted in conjunction with CMP studies; this applies whether the assessments are performed in-house or by a service provider; the service provider shall be qualified for both RBI and CMP. CMP finding should be reflected on completed RBI assessments and vice-versa

6. The inventory Loops shall be concurred to by the Plant Process Engineer. 7. If the assessment includes any API 650/620/12C tanks the environmental sensitivity requires concurrence by the Environmental Protection Department. 8. The assumptions shall be concurred to by the SA RBI Team Leader. 9. All RBI Databases, Inspection Plans and Risk Analysis’s for initial or evergreened RBI assessments require concurrence by an ID RBI Team member. 10. All RBI assessments for initial or evergreened require concurrence by a ID RBI Team member

Page 69 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Appendix 13 - Environmental Sensitivity FACILITY Abandoned Chemical Storage Facilities Abqaiq GOSP 2

Ownership / Department

Risk High Medium

Low

Material Planning & System Department

x

North Ghwar Producing Department

x

Abqaiq GOSP 3

North Ghwar Producing Department

x

Abqaiq GOSP 5

North Ghwar Producing Department

x

Abqaiq GOSP 6

North Ghwar Producing Department

x

Abqaiq Pipelines

Southern Area Pipeline Department

Ain Dar GOSPs (1 & 2)

North Ghwar Producing Department

x

Ain Dar GOSPs (1 & 2)

North Ghwar Producing Department

x

Al-Hasa BP

Eastern Region Distribution Department

Al-Jouf BP

Western Region Distribution

Berri Gas Plant

Berri Gas Plant

Dhahran AFO

Air Fueling Operations Department

x

Dhahran BP

E/C Region Distribution Department

x

Dhahran Hills Water Wells

Central Area Community Department

Duba BP

Western Region Distribution

Haradh

Southern Area Producing

x

Hawiyah

x

Jeddah Refinery

Southern Area Producing Jeddah Refinery Department

x

Jizan BP

Western Region Distribution

x

Ju’aymah Area(COT)

Terminal Department

x

Ju’aymah Gas Plant

Juaymah NGL Fractionation Dept

x

KAIA AFO

Air Fueling Operations Department

x

KFIA AFO

Air Fueling Operations Department

x

Khurais

Khurais Producing Dept

x

Khurasaniyah Producing Field

x

Najran BP

Ras Tanura Producing Dept Western Region Distribution Department

North Jeddah BP

Western Region Distribution Department

x

Pump Station 1

East-West Pipelines Dept

x

Pump Station 10

East-West Pipelines Dept

x

Pump Station 11

East-West Pipelines Dept

Pump Station 2

East-West Pipelines Dept

Pump Station 3

East-West Pipelines Dept

Pump Station 4

East-West Pipelines Dept

x

x x x

x x

x

x x x x Page 70 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

FACILITY

Ownership / Department

Risk High Medium

Low x

Pump Station 5

East-West Pipelines Dept

Pump Station 6

East-West Pipelines Dept

Pump Station 7

East-West Pipelines Dept

x

Pump Station 8

East-West Pipelines Dept

x

Pump Station 9 Qassim BP

East-West Pipelines Dept C/E Region Distribution Department

Qatif BP

C/E Region Distribution Department

Rabigh Bulk Plant Ras Tanura N&S Terminals

Western Region Distribution Dept Terminal Department

x

Ras Tanura Refinery

Ras Tanura Refinery

x

Riyadh Air Base

Air Fueling Operations Department

Riyadh Refinery & Bulk Plants

Pipelines, Distribution & Terminals

Safanyia & Tanajib Plants Safanyia BP Shedgum Sulayyil BP Tabouk AFO

x

x x x x

x x

Northern Area Oil Operations E/C Region Distribution Department

x

Southern Area Producing E/C Region Distribution Department

x

x x x

Tabouk BP

Eastern Region Distribution Dept Western Region Distribution Department

x

Taif AFO

Western Region Distribution Dept

x

Turaif BP

Western Region Distribution Dept

x

Uthmaniyah

x

Yanbu COT

Southern Area Producing Terminal Department

Yanbu Gas Plant

Yanbu NGL Fractionation Dept

Yanbu Refinery

Yanby Refinery Department

x x x

Page 71 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Index 1

Scope ............................................................................................................................. 2

2

Purpose.......................................................................................................................... 2

3

Conflicts and Deviations ................................................................................................. 2

4

Applicable Documents .................................................................................................... 3 4.1

Saudi Aramco Documents................................................................................................... 3

4.2

Industry Codes and Standards ............................................................................................ 4

5

Definitions and Abbreviations ......................................................................................... 5

6

Instructions ................................................................................................................... 12

7

6.1

RBI Methodology ............................................................................................................... 12

6.2

Equipment Grouping ......................................................................................................... 13

6.3

Inventory Group ................................................................................................................. 14

6.4

Equipment/Component Items in Plant Facilities ............................................................... 14

6.5

Off-Plot Piping ................................................................................................................... 14

6.6

Utilities ............................................................................................................................... 15

6.7

Offshore Facilities .............................................................................................................. 15

6.8

Above Ground Atmospheric Storage Tanks...................................................................... 15

6.9

PRDs ................................................................................................................................. 15

6.10

RBI Documentation ........................................................................................................... 15

6.11

Record Keeping ................................................................................................................. 16

6.12

Degradation Mechanism ................................................................................................... 17

6.13

Inspection Effectiveness Tables ........................................................................................ 17

6.16

Update of RBI Software Database .................................................................................... 19

6.18

Comprehensive Review of the OSI Program .................................................................... 19

Responsibilities ............................................................................................................ 22 7.1

ES RBI Team .................................................................................................................... 22

7.2

Team Leader ..................................................................................................................... 23

7.3

RBI Facilitator .................................................................................................................... 24

7.4

Sr. Inspection Engineer or Inspection Engineer ................................................................ 24

7.5

Materials/Corrosion Engineer ............................................................................................ 24

7.6

Plant Engineer ................................................................................................................... 25

7.7

RBI Software Practitioner .................................................................................................. 25

Page 72 of 73

Document Responsibility: Inspection Engineering Standards Committee SAEP-343 Issue Date: 7 July 2015 Next Planned Update: 21 August 2018 Risk-Based Inspection (RBI) for Saudi Aramco Facilities 7.8

Operations Personnel........................................................................................................ 25

7.9

Proponent Management .................................................................................................... 26

7.10

Loss Prevention Engineer ................................................................................................. 26

7.11

T&I Engineer ..................................................................................................................... 26

Appendix 1 – Decision Tree for Performing RBI ..................................................................... 27 Appendix 2 – RBI RASCI Chart .............................................................................................. 28 Appendix 3 – RBI Process for In-House Assessment ............................................................. 29 Appendix 4 – RBI Process for Service Providers .................................................................... 30 Appendix 5 – RBI Workflow for Tracking Recommendations.................................................. 31 Appendix 6 – Corrosion Loop Development Workflow............................................................ 32 Appendix 7 – RBI Task List .................................................................................................... 33 Appendix 8 – Description of RBI Tasks .................................................................................. 34 Phase 1 – Pre-Assessment Preparation ....................................................................................... 34 Phase 2 – Data Collection ............................................................................................................. 35

Appendix 9 – Sources of Site Specific Data and Information .................................................. 46 Appendix 10 – Inspection Effectiveness Tables ..................................................................... 48 Appendix 11 – RBI Validation Form ....................................................................................... 68 Appendix 12 – RBI Validation Form Instructions .................................................................... 69 Appendix 13 - Environmental Sensitivity ................................................................................ 70

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