Petroleum Development Oman L.L.C.
UNRESTRICTED
May 2005
Document ID : PR-1013
Filing key : EP.72
Static Equipment
Inspection and Maintenance Procedure
Mansoor Abdally, UEC/15
Keywords:
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any
part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
Static Equipment Inspection & Maintenance Procedure
Version 3.0
Authorised For Issue 31/05/2005
Signed :...........................................................
Rashid Al Harthy, UOM
CFDH Maintenance
Signed :...........................................................
Mansoor Al Abdally, UEC/15
Head of Static Equipment Inspection
CDFP Static Equipment Maintenance
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
Version No.
Version 3.0
Date
May 05
Version 2.0
Verison 1.0
Jul 98
Mar 98
31/05/2005
Author
Mansoor Abdally,
UEC/15
Mike Clarke, UOM/3
Mike Clarke, UOM/3
Page i
Scope / Remarks
New Revision
First Revision
New Procedure – Initial Issue
PR-1013
Version 3.0
Static Equipment Inspection & Maintenance Procedure
Contents
Authorised For Issue 31/05/2005 ................................................................................................. i
Contents....................................................................................................................................... ii
1.
Introduction .................................................................................................................... 1
Background ................................................................................................................ 1
Purpose ....................................................................................................................... 1
Distribution/Target Audience..................................................................................... 1
Structure of This Document ....................................................................................... 1
1.1
1.2
1.3
1.4
2.0
Scope .............................................................................................................................. 2
Scope .......................................................................................................................... 2
2.1
3.0
Static Equipment Inspection and Maintenance Procedure ............................................ 3
Procedure Description ..................................................................................... 3
Upkeep of Asset Register................................................................................ 3
Work Management.......................................................................................... 3
Inspection & Maintenance Planning ............................................................... 3
Preparation for Inspection & Maintenance ..................................................... 4
Inspection & Maintenance Processes ............................................................. 4
Static Equipment Inspection & Maintenance.................................................. 5
Static Equipment Corrosion Management .................................................... 10
Static Equipment Repairs .............................................................................. 11
Static Equipment Re-Certification ................................................................ 11
Inspection Records & Reporting................................................................... 12
Corrosion Data Storage & Management ....................................................... 13
Fitness For Purpose Assessment ................................................................... 13
Management Review and Performance Measurement .................................. 13
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
4.0
Procedure Administration ........................................................................................... 15
4.1
4.2
4.3
4.4
4.5
Roles and Responsibilities........................................................................................ 15
Execution of the Procedure ...................................................................................... 15
Related Business Control Documents ...................................................................... 15
Review and Improvement......................................................................................... 16
Step-out and Approval............................................................................................. 16
Appendix
A1 Glossary of Terms, Definitions & Abbreviations ................................... 17
Appendix
A2 Static Equipment Inspection & Maintenance Process Maps .................... 1
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Static Equipment Inspection & Maintenance Procedure
1.0
Introduction
1.1
Background
Version 3.0
This procedure provides the structured process for static equipment inspection.
1.2
Purpose
The purpose is to describe the procedure for maintaining and demonstrating the technical
integrity of static equipment.
1.3
Distribution/Target Audience
Operations Team Leaders, Area Co-ordinators, Area Maintenance Engineers, Corporate
Functional Discipline Head (CFDH) and Corporate Discipline Focal Points (CDFP's) for
Maintenance and Operations, Area Planning Engineers, Engineering Planners, Area
Planners, Corporate Activity Planner, Discipline Supervisors, Asset Maintenance
Supervisors and Planners.
1.4
Structure of This Document
This document is structured as follows:
Section 1
Contains an introduction to the document
Section 2
Defines the scope
Section 3
Describes the procedure
Section 4
Details roles and responsibilities of key personnel concerned with the
document and provides other procedure administration
Appendices
A1 is the Glossary of Terms, Definitions and Abbreviations.
A2 contains maps of the life cycle integrity processes for static equipment
inspection & maintenance
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2.0
Scope
2.1
Scope
This procedure applies to operations phase inspection and maintenance of the following
static equipment types:
•
Tanks
•
Vessels
•
Heat Exchangers
o
Shell & Tube
o
Fin Fan Type
o
Plate Type
o
Fired Heaters / Furnaces
•
Columns
•
Sumps
•
On-Plot Piping
•
Flowlines
•
Relief Valves
•
Lifting Equipment
This document does not give details of static equipment inspection & maintenance strategies.
The reader is referred to SP-XXXX ‘Static Equipment & Flowlines RBI Process’ for such
information.
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Static Equipment Inspection and Maintenance
Procedure
3.1
Procedure Description
Version 3.0
The steps in the procedure for static equipment inspection and maintenance are generally as
follows:
•
Upkeep of Asset Register
•
Work Management
•
Inspection & Maintenance Planning
•
Preparation for Inspection & Maintenance
•
Inspection Processes
•
Inspection Records & Reporting
•
Corrosion Data Storage and Management
•
Fitness For Purpose Assessment
•
Management Review and Performance Measurement
3.1.1
Upkeep of Asset Register
The Asset Register for all static equipment is held within SAP and the Asset Owner is
responsible for the upkeep of the register.
In the case of the static equipment inventory of a new project, the Project team inputs the
information into SAP as part of the project deliverable. Thereafter the Asset Owner maintains
the data as above.
PACER-CM is used by UEC for the management of corrosion data and the corresponding
determination of inspection due dates of static equipment from the data. In order to maintain a
common asset register between PACER and SAP, UEC team periodically update the PACERCM database from SAP using a specially developed parametric data transfer routine.
3.1.2
Work Management
Maintenance and Inspection of all PDO Static Equipment assets is addressed through the SAP
System. There are no exceptions to this for Work Order management.
3.1.3
Inspection & Maintenance Planning
The risk based inspection method determines and assigns a risk profile to asset tag items. This
risk category together with the remaining life of the item (estimated from inspection data) is
used to determine the priority of what tags should be inspected and when. The required
inspection tasks are then set out in inspection strategies graded to suit the different risk
categories and generic equipment types. In a similar way, preventive maintenance tasks and
frequencies are also determined and set out in generic risk based maintenance strategies.
Having determined the inspection and maintenance tasks and their periodicity, this information
is then used to produce an integrated activity plan for the asset. This is a very well established
SAP process documented elsewhere and will not be elaborated further here.
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Inspection and maintenance are always included in the integrated activity plan in line with the
requirements of the IAP system. Planned maintenance due dates are determined directly within
the SAP system. However, inspection due dates are determined directly within the PACER-CM
system and therefore need to be entered into the SAP system to ensure that all maintenance and
inspection resource planning is driven only from the SAP database.
In order to include the correct inspection data in SAP, UEC/15 team first of all download the
inspection due dates calculated in the PACER-CM system. This data is then worked into an
inspection ‘campaign’ schedule for the forthcoming year. When this schedule is finalised the
data is then uploaded into the SAP system.
Deviation from planned inspection due dates requires the specific approval of CDFP Static
Equipment. PR-1005 ‘Maintenance & Inspection Activity Variance Control’ procedure refers.
3.1.4
Preparation for Inspection & Maintenance
Preparation and planning for inspection are set out in the guideline ‘Static Equipment Inspection
Guideline’ GU-256, and also generically at equipment item level in the procedure “Preparation
of Static Equipment for Intrusive Maintenance’ PR-1077.
The broad principles of preparation for Inspection & Maintenance are mentioned below:
• Equipment design
• Operational context
• Logistics
3.1.4.1
Equipment Design
Inspection and maintenance staff must be fully versed in the design of the subject equipment
item. This requires a full review of relevant engineering, maintenance and inspection data about
the equipment. Detail drawings, vendor data books, and manufacturers O&M manuals should
be referred to at the earliest stages of preparation.
3.1.4.2
Operational Context
Inspection and maintenance staff are obliged to confer and consult with operations colleagues
about the subject equipment because the asset owner and the operations team are the primary
customers of inspection & maintenance processes. The operations team know the current
operational performance of the equipment. This information will have a direct bearing on the
scope of any intended inspection or maintenance. Time spent on liaison with operations
colleagues is the best professional way to bring clarity and understanding to all parties on the
operational context in which the inspection & maintenance processes will be delivered. This is
essential to good preparation.
3.1.4.3
Logistics
Major inspection and maintenance work needs to be planned well in advance. Given the
extensive nature and spread of PDO facilities, critical preparation logistics of major activity
must be started at the earliest possible time to ensure minimum business outage of the item
concerned.
3.2
Inspection & Maintenance Processes
Static Equipment maintenance management and execution processes are grouped into the
following areas of interest:
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•
Static Equipment Inspection & Maintenance
•
Static Equipment Corrosion Management
•
Static Equipment Repairs
•
Static Equipment Re-Certification
Version 3.0
Appendix A2 shows the life cycle integrity process maps which comprise the above areas of
interest. The processes are described below.
3.2.1
Static Equipment Inspection & Maintenance
3.2.1.1
Tank Internal Inspection
This process refers to the Tank ‘thorough internal inspection’ which is the most important and
reliable of all inspections in the determination of Tank condition. It is an intrusive process
requiring man entry. Therefore all the associated logistics and PTW processes are required.
Typically required would be, an approved method statement / job plan, physical isolation, preinspection cleaning, gas testing and clearing, safe access, and standby safety attendance for
example. PR-1077 ‘Preparation of Static Equipment for Intrusive Maintenance’ refers.
Detailed, integrated planning is essential. Some Tanks require a Station shutdown and therefore
require oil deferment planning. For that reason, Internal Tank Inspections are always included
in the Integrated Activity Plan.
The scope of work involved would include associated ‘opportunity’ work such as change-out or
maintenance of tank-side isolation valves and instrumentation, in addition to the inspection
work. In those cases where internal sacrificial anodes are installed in Tanks, they would be
physically assessed at this inspection and replaced if necessary as part of the workscope.
Either the Asset Maintenance Team or the Maintenance Contractor would normally perform the
logistics of isolation, preparation for the inspection, repairs if required and box-up of the Tank
to bring back into service.
Inspection would be performed by UEC/15 and their Inspection Contractor. If specialist
inspection services are required, UEC/15 would make the necessary arrangements.
The PDO approach with regard to internal inspections is in three stages as follows:
Initial Inspection:
This is the internal inspection of the Tank which would reveal tank condition. Visual and NDE
methods would be employed. The inspector would write the inspection report and issue to
UEC/15 group and the Asset and Maintenance Team. In the event of some immediate
restoration being required to the Tank, and after weighing up all the factors, UEC/15 would
recommend corrective action to Asset and copy to Maintenance Team. On the instruction of
the Asset Owner to proceed with remedial work, Maintenance Team and if the job is large
enough, a Project Engineer would produce a detailed scope of work to restore the condition of
the Tank.
Intermediate Inspection:
An intermediate inspection is only included for larger scopes of work. The purpose is to ensure
that the initial requirements are being correctly addressed with regard to both content and
quality of work.
Final Inspection:
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This inspection is to ensure that the full scope of work has been properly completed and that the
necessary job records and documents are available for the Inspection Files.
On completion of remedial work UEC/15x would issue a ‘Notification’ to box-up the Tank.
UEC/15x would then determine the next inspection due date by referring to SP-XXXX ‘Static
Equipment & Flowlines RBI Process’ and enter that date into SAP.
With regard to Tank Internal Inspection, the following NDE techniques would normally be
used:
•
Roof
Manual UT
•
Shell
Manual UT
•
Nozzles
Manual UT
•
Floor
MFL
•
Lining
Holiday Test
Inspection is performed by UEC/15 and their Inspection Contractor. If specialist inspection
services are required, UEC/15 would make the necessary arrangements.
The Inspection Reports would be filed in the appropriate location.
3.2.1.2
Tank External Inspection
This is a non-intrusive External Inspection performed between Tank Internal Inspections to
monitor the ongoing tank condition. As such it is less onerous to perform because the
preparation workload is generally less.
With regard to Tank External Inspection, the following NDE techniques would normally be
used:
•
Roof
Manual UT
•
Shell
Manual UT
•
Nozzles
Manual UT
•
Floor
Acoustic Emission
Inspection would be performed by UEC/15 and their Inspection Contractor. If specialist
inspection services are required, UEC/15 would make the necessary arrangements.
In the event that no anomaly or a minor anomaly is found, UEC/15x would simply confirm the
next inspection due date and enter that due date in SAP.
In the event that a major anomaly is found UEC/15x would investigate in more detail to confirm
the extent of the anomaly in order to perform a risk assessment. The outcome of the risk
assessment would direct the corrective action recommendation and the determination of next due
inspection date. A Notification would be issued to the Asset to advise of the changed integrity
status of the Tank. Remedial action would be planned into the integrated activity plan consistent
with the risk priority allocated.
3.2.1.3
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This process refers to the Vessel ‘thorough internal inspection’ which is the most important and
reliable of all inspections in the determination of Vessel condition. It is an intrusive process
requiring man entry. Therefore all the associated logistics and PTW processes are required.
Typically required would be, an approved method statement / job plan, physical isolation, preinspection cleaning, gas testing and clearing, safe access, and standby safety attendance for
example. PR-1077 ‘Preparation of Static Equipment for Intrusive Maintenance’ refers.
Detailed, integrated planning is essential. Some Vessels require a Station shutdown and therefore
require oil deferment planning. For that reason, Internal Vessel Inspections are always included
in the Integrated Activity Plan.
The scope of work involved would include associated ‘opportunity’ work such as change-out or
maintenance of Vessel-side isolation valves and instrumentation, in addition to the inspection
work.
Inspection would be performed by UEC/15 and their Inspection Contractor. If specialist
inspection services are required, UEC/15 would make the necessary arrangements.
Corrosion data is entered into PACER-CM which determines inspection due dates. PACER also
identifies the life limiting factors. The Integrity Engineer would finally decide the next inspection
date after weighing all the relevant information.
The PDO approach with regard to internal inspections is in three stages as follows:
Initial Inspection:
This is the internal inspection of the Vessel which would reveal Vessel condition. Visual and NDE
methods would be employed. The inspector would write the inspection report and issue to UEC/15
group and the Asset and Maintenance Teams. In the event of some immediate restoration being
required to the Vessel, and after weighing up all the factors, UEC/15 would recommend corrective
action to Asset and copy to Maintenance Team. On the instruction of the Asset Owner to proceed
with remedial work, the Maintenance Team and if the job is large enough, a Project Engineer,
would produce a detailed scope of work to restore the condition of the Vessel.
Intermediate Inspection:
An intermediate inspection is only included for larger scopes of work. The purpose is to ensure that
the initial requirements are being correctly addressed with regard to content and quality of work.
Final Inspection:
This inspection is to ensure that the full scope of work has been properly completed and that the
necessary job records and documents are available for the Inspection Files.
On completion of remedial work UEC/15x would issue a ‘Notification’ to box-up the Vessel.
UEC/15x would then determine the next inspection due date by referring to SP-XXXX ‘Static
Equipment & Flowlines RBI Process’ and enter that date into SAP.
The Inspection Reports would be filed in the appropriate location.
3.2.1.4 Vessel External Inspection
This is a non-intrusive interim Vessel External Inspection performed between Vessel Internal
Inspections to monitor the ongoing Vessel condition. As such it is less onerous to perform because the
preparation workload is generally less.
Inspection would be performed by UEC/15 and their Inspection Contractor. If specialist inspection
services are required, UEC/15 would make the necessary arrangements.
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Corrosion data is entered into PACER-CM which determines inspection due dates. PACER also
identifies the life limiting factors. The Integrity Engineer would finally decide the next inspection date
after weighing all the relevant information.
In the event that no anomaly or a minor anomaly is found, UEC/15x would simply confirm the next
inspection due date and enter that due date in SAP.
In the event that a major anomaly is found UEC/15x would investigate in more detail to confirm
presence and extent of the anomaly in order to perform a risk assessment. The outcome of the risk
assessment would direct the corrective action recommendation and the determination of next due
inspection date. A Notification would be issued to the Asset to advise of the changed integrity status
of the Vessel. Remedial action would be planned into the integrated activity plan consistent with the
risk priority allocated.
3.2.1.5 Heat Exchanger Internal Inspection
This process refers to the Heat Exchanger ‘thorough internal inspection’ which is the most important
and reliable of all inspections in the determination of Heat Exchanger condition. It is essentially an
intrusive process. Man entry would be required in the case of Fired Heaters and Furnaces, but not in
the case of S&T, Fin Fan or Plate types.
All the associated logistics and PTW processes are required. Typically required would be, an approved
method statement / job plan, physical isolation, pre-inspection cleaning, gas testing and clearing, safe
access, and standby safety attendance for example in those cases where man entry is possible. PR1077 ‘Preparation of Static Equipment for Intrusive Maintenance’ refers.
Detailed, integrated planning is essential. The scope of work involved would include associated
‘opportunity’ work such as change-out or maintenance of Heat Exchanger-side isolation valves and
instrumentation, in addition to the inspection work.
Either the Asset Maintenance Team or the Maintenance Contractor would normally perform the
logistics of isolation, preparation for the inspection, repairs if required and box-up of the Heat
Exchanger to bring back into service.
Inspection would be performed by UEC/15 and their Inspection Contractor. If specialist inspection
services are required, UEC/15 would make the necessary arrangements.
With the exception of Fired heaters / Furnaces, all corrosion data would be entered into PACER-CM.
The PACER data would be used in the determination of next inspection due date. PACER would also
identify any life limiting factors.
In all cases, the Integrity Engineer would decide the next inspection due date after weighing all the
relevant information including PACER-CM data where relevant.
The PDO approach with regard to internal inspections is in three stages as follows:
Initial Inspection:
This is the internal inspection of the Heat Exchanger which would reveal Heat Exchanger condition.
Visual and NDE methods would be employed. The inspector would write the inspection report and
issue to UEC/15 group and the Asset and Maintenance Team. In the event of some immediate
restoration being required to the Heat Exchanger, and after weighing up all the factors, UEC/15 would
recommend corrective action to Asset and copy to Maintenance Team. On the instruction of the Asset
Owner to proceed with remedial work, Maintenance Team, and if the job is large enough, a Project
Engineer, would produce a detailed scope of work to restore the condition of the Heat Exchanger.
Intermediate Inspection:
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An intermediate inspection is only included for larger scopes of work. The purpose is to ensure that
the initial requirements are being correctly addressed with regard to content and quality of work.
Final Inspection:
This inspection is to ensure that the full scope of work has been properly completed and that the
necessary job records and documents are available for the Inspection Files.
On completion of remedial work UEC/15x would issue a ‘Notification’ to box-up the Heat Exchanger.
UEC/15x would then determine the next inspection due date by referring to SP-XXXX ‘Static
Equipment & Flowlines RBI Process’ and enter the date into SAP.
The Inspection Reports would be filed in the appropriate location.
3.2.1.6
On-Plot Pipework Inspection – Baseline
The purpose of this process is to collect baseline data from new or relatively new On-Plot Pipelines.
The process begins from new facilities projects where new piping data is collected and entered into
SAP. From SAP it is downloaded into PACER by UEC/15 group. The UEC/15 Inspection Contractor
generates the necessary pipeline isometrics for the baseline and ongoing inspections. The piping
isometrics are then marked up with the required inspection key points. The isometric drawings are
used by the UEC/15 Team or their Inspection Contractor to collect the baseline data which is then
reported.
The data from the report is entered into PACER-CM database by UEC/15D. PACER calculations are
run to determine:
•
Remnant Life
•
Next Due Inspection Date
The next due inspection date is then input to SAP.
3.2.1.7
On-Plot Pipework Inspection – Ongoing
Inspection would be performed by UEC/15 or their Inspection Contractror using the baseline isometric
drawings referred to above as the inspection template.
Corrosion data is recorded as the work progresses and is ultimately entered into PACER-CM which
determines next inspection due date. The Integrity Engineer would finally decide the next inspection
due date after weighing all the relevant information.
In the event that no anomaly or a minor anomaly is found, UEC/15x would simply confirm the next
inspection due date and enter that due date in SAP.
In the event that a major anomaly is found UEC/15x would investigate in more detail to confirm the
extent of the anomaly in order to perform a risk assessment. The outcome of the risk assessment would
direct the corrective action recommendation and the determination of next due inspection date. A
Notification would be issued to the Asset to advise of the changed integrity status of the On-Plot
Pipeline. Remedial action would be planned into the integrated activity plan consistent with the risk
priority allocated.
3.2.1.8
Flowline Inspection
UEC/15 Inspection Contractor performs the flowline inspections in two stages, firstly using an MFL
tool to identify defects and secondly manual UT to map any defects found. 100% of the bottom
segment of the pipe is inspected by MFL on oil and gas/condensate flowlines, and 100% of the top
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segment of the pipe is inspected by MFL on water lines. Manual UT is deployed only when a
significant anomaly is found by MFL.
The method is as follows. The tool is preset to locate and signal a limiting wall thickness. The MFL
tool is then manually traversed along the pipe run under survey. When the MFL tool locates such an
anomaly, the location is marked on the pipe and followed up by a supporting team using manual UT to
map the defect details. The UT data is recorded in a UT report for the flowline concerned.
In the event that no anomaly or a minor anomaly is found, UEC/15x would simply confirm the next
inspection due date and enter that due date in SAP.
In the event that a significant anomaly is found, the data in the UT report would be entered into a risk
based assessment model along with flowline parameters from PACER-CM. The outcome of the risk
assessment would direct the corrective action recommendation and the determination of next
inspection due date. A Notification would be issued to the Asset to advise of the changed integrity
status of the Flowline. Remedial action would be planned into the integrated activity plan consistent
with the risk priority allocated.
3.2.1.9
Buried Piping Sections
Throughout the static equipment system, there are buried sections of pipeline, typically at crossings but
also due to blown sand. Whether and how to inspect such lines has to be considered by the Static
Inspector based on pipeline criticality and economics. The methods used may range from full exposure
of the pipeline for close examination and manual UT, to the use of LR-UT. If in doubt the Static
Inspector would refer to UEC/15 for guidance.
3.2.2
Static Equipment Corrosion Management
3.2.2.1
Cathodic Protection
Impressed current Cathodic Protection is the primary PDO method of external corrosion mitigation
which accounts for 99% of PDO CP and is largely applied to pipelines, tank bottoms and buried
vessels. In areas where the installation of impressed current CP cannot be justified on economical
grounds, or where the use is not appropriate, the installation of Sacrificial Anode CP is used.
For Tanks, and some very large Vessels a Sacrificial Anode CP system is applied internally.
The monitoring process is performed every 3 months, and every 12 months with a slight variation to
the monitoring routine.
The routines involve On/Off Potential measurements at every CP Potential Testing Location,
Groundbed Potential Measurement and Full 24 hr Current Test for all Solar Power CP Units.
Measurements are recorded in PACER CM. Quarterly Reports and Deficiency Lists are prepared. The
Deficiency Lists go to the CSR for appropriate follow up, and the Quarterly Reports are held in a
Library facility for ongoing reference. The Corrosion Engineer analyses the reports and data to
determine corrective action.
Further to routine data collection, every year a formal ACR (Assessed Corrosion Rate) is carried out.
The ACR process underpins the external corrosion management corrective action, strategy
improvement and updating of Static Equipment Reference Plans.
SAP is the vehicle for Work Order Management, Contractor invoice clearance, and also for updated
basic engineering data.
3.2.2.2
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This technique is not normally used for static inspection activities but remains an option under some
circumstances.
This is a combined CIPS (Close Interval Potential Survey) and DCVG (Direct Current Voltage
Gradient) survey.
CIPS assesses the CP ( Cathodic Protection) effectiveness over the entire length of a pipeline
between permanent test stations.
DCVG is used for locating coating defects in buried pipelines.
3.2.3
3.2.3.1
Static Equipment Repairs
Static Equipment Repairs
Static Equipment repairs / restoration may be required as a result of inspection work. The
process normally begins with a recommendation from UEC/15x. A scope of work would then
be prepared by the Asset Maintenance Team or if the job is of sufficient size, Project
Engineering. UEC/11 would review the scope of work and also generate the QA/QC Plan.
Throughout the completion of the scope of work inspections would be performed by the
UEC/15 Inspector, and the whole QA/QC Plan would be monitored by UEC/11.
On successful completion of remedial work, UEC/15x would issue a Notification to the Asset
Maintenance Team to box-up the equipment. The next due date would be entered into SAP and
the inspection and repair records filed in the Inspection Files.
3.2.4
3.2.4.1
Static Equipment Re-Certification
RV Re-Certification
All Relief Valves are registered in SAP.
Relief valve re-certification is scheduled from SAP and included in the integrated activity plan.
Oil deferment planning may be required. Maintenance strategy / repair philosophy would
impact the workscope. In some cases the RV for re-certification may be directly changed-out
with another identical spare unit already re-certified for the duty.
The essence of this process is witnessing / recording and the involvement of the UEC/15
Inspector where appropriate.
The condition of the RV ‘as removed’ is recorded. The unit is then removed to the workshop
RV test bench facility, where the RV settings ‘as removed’ are checked and recorded. The RV
is then stripped and overhauled taking special note of any material inconsistencies revealed by
examination of the component parts. The valve is then re-assembled in as-new condition, and
re-set on the test rig.
When the RV re-assembly and setting is certified as correct by UEC/15x, the RV is sealed to
prevent tampering, and suitably packaged for warehouse storage in the meantime until the RV is
next required for duty.
All records are entered in SAP and hard copy certification filed in the item inspection file.
3.2.4.2
Lifting Equipment Re-Certification
All Lifting Equipment is registered in SAP.
Lifting Equipment is typically defined as follows:
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Lifting Gear:
•
Chains and Chain slings
•
Shackles & Pins
•
Ropes and Rope slings
•
Nylon and webbing strops
•
Geared Beam Trolleys
•
Beam Clamps
Lifting Appliances
•
Mobile Cranes
•
Fork Lift Trucks
•
Hyab Trucks
•
A-Frames
•
Hand Pallet Trolleys
•
Rated HE Tube Bundle pullers
•
Rated Maintenance trolleys
•
Pull Lift devices
•
Chain Blocks
•
Gantry Cranes
•
Hoists
•
Lifting Beams
The re-certification process normally comprises four stages, namely:
•
collection / location / identification of all lifting equipment
•
inspection (and function testing as appropriate) of lifting equipment
•
Re-certification and colour coding of items considered safe for continued use
•
Quarantine for repair and/or destruction of items not considered safe for continued use
The use of UEC/15 Inspector or Third Party Inspectors is mandatory and in some cases a legal
requirement. All Certification is kept in the item Inspection File.
3.2.5
Inspection Records & Reporting
Inspection Records and Reports are held for each item of Static Equipment, located as follows:
PR-1013
12
31/05/2005
Static Equipment Inspection & Maintenance Procedure
OND
Fahud
OSD
Marmul
MAF
Coast
Version 3.0
The contents of the files follow traditional requirements such as:
•
Equipment Drawings
•
Vendor Data
•
Original Materials Certificates
•
‘Renewable’ Test Certificates
•
Previous Inspection Reports
3.2.6
Corrosion Data Storage & Management
In the case of corrosion data acquisition and storage for the purposes of Static Equipment
corrosion management and inspection, PACER is the expert database used to determine remnant
life and next inspection due date. The current exceptions to the use of PACER are:
•
Tanks
•
Fired Heaters
•
Furnaces
In the above cases a combination of factors would be considered by the Integrity Engineer to
determine next due inspection date. The internal condition revealed by inspection, industry
standards and norms, and a risk based / time based interval approach based on confidence in the
ability to predict the item degradation rate, directs the Integrity Engineer’s determinations.
3.2.7
Fitness For Purpose Assessment
In the event that an inspection reveals a major anomaly which may impact the integrity of the
item, a fitness for purpose assessment is required to ascertain what remedial action to take. This
is performed by the inspection / integrity engineer.
The primary requirement is to determine whether or not the anomaly of concern is outwith the
necessary minimum wall thickness criterion for the item of equipment. If the anomaly fails the
criterion acceptance level for the item, repair or replacement would normally be specified. In
certain cases, especially continued operation in the short term without immediate restoration of
the item, a more detailed assessment shall be required by the inspection / integrity engineer to
ensure that under the specified operation conditions the risks are as low as reasonably practical.
The planning and scheduling of any required remedial maintenance of static equipment is
progressed via a Z1 notification raised in SAP. The repair process is then as generally
described above in the section titled “Static Equipment Repairs”.
3.2.8
Management Review and Performance Measurement
Management review and performance measurement of the inspection process is addressed via
the following means:
•
PR-1013
Integrity Status Reports
13
31/05/2005
Version 3.0
•
Remnant Life Reports
•
KPIs
Static Equipment Inspection & Maintenance Procedure
The data for the above is extracted from PACER-CM by way of Business Objects software, and
presented in report form by the Inspection / Integrity Engineer.
PR-1013
14
31/05/2005
Static Equipment Inspection & Maintenance Procedure
4.0
Procedure Administration
4.1
Roles and Responsibilities
Version 3.0
Define who must carry out each step in the procedure. Optionally, this may be included in the
procedure description. Describe roles and responsibilities, if necessary, in the following tabular
format:
ROLE
UEC/15
UEC/15X
UEC/152
4.2
RESPONSIBILITY
Head of Static Equipment Inspection and Maintenance
CDFP
Senior Static Equipment Inspector for the Assets
Senior Lifting Equipment Inspector
Execution of the Procedure
This procedure is to be followed on a continual basis.
4.3
Related Business Control Documents
Policy
Code of Practice
Asset Integrity.
Maintenance Code of Practice
PL-11
CP-114
SP-XXX
SP-1210
SP-1211
Procedures
Static Equipment & Flowlines RBI Process
Pipelines Operation & Maintenance
Pipelines Engineering
Activity Planning
Pig Launcher / Receiver Maintenance Procedure
BVS Maintenance Procedure
Order for Services Procedure
CP Monitoring & Surveying Procedure
CIPS Procedure
DCVG Procedure
Auto UT Inspection Procedure
Manual UT Inspection Procedure
External Corrosion Verification Procedure
Sleeving, Clock-Spring and Fleximat Procedure
COSASCO Operations and Maintenance Manual
Coating Procedures
Contractor Procedures
Maintenance & Inspection Activity Variance
Control Procedure
Preparation of Static Equipment for Intrusive
Maintenance
Procedures for the use of Pipe RBA
Procedure for Determining Pipeline ACR
Static Equipment Inspection Guideline
Guidelines for the Protection of Buried Sections of
Surface Laid Pipelines / Flowlines
Maintenance Management Guideline -MMG
MMG – Maintenance Reference Plan
MMG – Integrity Management
MMG – Risk Based Inspection
Jan 2005
PR-1005
PR-1077
PR-1416
PR-1503
GU-256
GU-368
Guideline
Guideline
Guideline
Guideline
PR-1013
15
Jan 2002
Jan 2005
April 2005
SIEP 98-5200
SIEP 98-5201
SIEP 98-5202
SIEP 98-5214
31/05/2005
Version 3.0
Guideline
Guideline
HSE Safety Case
4.4
Static Equipment Inspection & Maintenance Procedure
MMG – Risk Based Inspection
Guideline to Pipeline Risk Based Maintenance
Key Operational Documents (KOD below)
KOD B3 – Hazard & Effects Register
KOD D – HSE Critical Tasks
SIEP 98-5215
OP.01.20087
2003
Review and Improvement
This procedure, which is owned by the CFDH Maintenance UOM, will be reviewed as
and when required. Recommendations for amendment to this procedure are to be
initially addressed to the CFDH Maintenance.
4.5
Step-out and Approval
Maintenance and Inspection Activity Variance Control Procedure PR-1005 defines the
requirements for a change in the timing of inspection tasks.
Operation Procedure Variance SI-14 defines the requirements for operating Static
Equipment outside the Design Envelope.
PR-1013
16
31/05/2005
Static Equipment Inspection & Maintenance Procedure
Appendix
A1
Version 3.0
Glossary of Terms, Definitions & Abbreviations
ACR
Asset Register
Assessed Corrosion Rate
A record listing and detailing equipment.
Availability
The proportion of a given time interval that an item or system is able to fulfil its
function.
Breakdown
Maintenance
Work carried out on equipment to address a defect which prevents the equipment from
being able to fulfil its function.
BVS
C&A
Campaign
Maintenance
Block Valve Station
Control & Automation
Maintenance activities carried out by roving maintenance teams. These activities have
a periodic frequency of at least 6 months.
CDFP
Corporate Discipline Focal Point.
CFDH
Corporate Functional Discipline Head.
CI
CIPS
CMS
Corrosion Inhibition
Close Interval Potential Survey
Computerised Maintenance System.
Corrective
Maintenance
Work carried out on equipment to address a defect which does not immediately prevent
the equipment from being able to fulfil its function.
CP
CSR
DCS
Cathodic Protection
Company Site Representative
Distributed Control System.
DCVG
EPBM
ESD
Direct Current Voltage Gradient
Exploration & Production Business Model
Emergency Shutdown.
F&G
Fire and Gas System.
FMEA
Failure Mode and Effect Analysis.
FMECA
IAP
Failure Modes Effects & Consequence Analysis
Integrated Activity Plan.
IDAS
Integrated Drawing and Information System.
IP
IPF
Intelligent Pigging
Instrument Protective Function.
MCP
Maintenance Craft Procedure.
MFL
Magnetic Flux Leakage.
NDE
Pacer-CM
Non Destructive Examination
Computerised Corrosion Management System.
Planned Maintenance
The maintenance organised and carried out with forethought, control and the use of
records, to a pre-determined plan.
PLC
Programmable Logic Controller.
PR-1013
17
31/05/2005
Version 3.0
Static Equipment Inspection & Maintenance Procedure
PM
Preventative Maintenance Routine.
RBA
RCA
Reliability
Risk Based Assessment
Root Cause Analysis
The ability of an item to perform a required function under stated conditions for a stated
period of time.
Reliability Centred
Maintenance (RCM)
A structured and auditable method for establishing the appropriate maintenance
strategies for an asset in its operating context.
Risk Based Inspection
(RBI)
An auditable method for establishing the frequency of equipment inspection, based on
the combined effect of the probability of the occurrence of an undesirable event and the
magnitude of the event.
Routine Maintenance
Maintenance work of a repetitive nature which is undertaken on a periodic basis.
ROW
RTU
SAP
Right of Way
Remote Transmission Unit
Exploration and Production Maintenance Administration and Reporting System.
SCADA
Supervisory Control and Data Acquisition.
Scheduled
Maintenance
Preventative maintenance carried out to a pre-determined interval of time or number of
operations, e.g. run hours.
TISC
UT
WO
Technical Integrity Streering Committee
Ultrasonic Testing
Work Order
PR-1013
18
31/05/2005
Static Equipment Inspection & Maintenance Procedure
Appendix
Version 3.0
A2 Static Equipment Inspection & Maintenance Process
Maps
The Static Equipment Inspection and Maintenance Process Maps are:
•
Tank Internal Inspection
•
Tank External Inspection
•
Vessel Internal Inspection
•
Vessel External Inspection
•
Heat Exchanger Internal Inspection (S&T, Fin Fan, and Plate)
•
Heat Exchanger Internal Inspection (Fired Heater, Furnace Types)
•
On-Plot Pipe Work Base Line Inspection
•
On-Plot Pipe Work Ongoing Inspection
•
Flow Line Inspection
•
Cathodic Protection
•
CIPS / DCVG Survey
•
Static Equipment Repairs
•
Relief Valve Re-Certification
•
Lifting Equipment Re-Certification
The maps are shown on the following pages.
PR-1013
1
31/05/2005
Static Equipment Inspection & Maintenance Procedure
Version 3.0
N o te 1:
S om e T anks requ ire S tatio n S /D
be ca use th e y are tie d into F la re
H ead e r
90 D P la n
T h is is an Inv asive p ro cess req u irin g M an E n try
N o te 2:
M ainly for T a nk flo or re qu irem en ts
10 0% M F L covera g e b y e xcep tio n
T o fo llow up an y de terio ration fo u nd
at set inspe ction po ints
A sse t T e a m
SAP
S T AR T
M o b ilise
T a n k In sp e cto r
R e vie w T a n k
In sp e ctio n File
U E C /1 5 x
IN S P E C T O R
In s p ec tio n File C o n tain s :
E quipm ent D ra win gs
V end o r d ata
O rigin al M a te rials C e rtificates
‘R ene w a ble ’ T e st C e rtificates
P revious In spection & M ainten anc e R ep orts
S ee N o te 1 ab ove
P ro vid e
In sp e ctio n S e rvice s
S ta tic E q u ip m e n t
In sp e ctio n
A g re e
1 4 D S ch e d u le
W ith O X O /xx
Iso la te a nd D ra in
T a n k for In sp e ctio n
P h ysica lly
Iso la te T an k
F o r M a n E n try
D e -S lu d g e T a n k
& C le an In te rn ally
Issu e
C o n fin e d S p a ce
E n try P TW
U E C /1
U E C /1 5
A re a P la n n e r
S ee
O X ON/1ote
x
A sse t M a in t T e a m
A sse t M a in t T ea m
O X O /1 x
H S E -C ritical T a sk R e fe rence :
A -0 6.01
A -0 6.02
A -0 6.03
A -0 6.04
A -0 6.05
A -0 6.06
A -0 6.07
A -0 6.01.0 5
A -0 6.01.0 6
A -0 6.01.0 7
A -0 6.02.0 1
A -0 6.02.0 2
A -0 6.02.0 3
A -0 6.04.0 1
A -0 6.04.0 2
A -0 6.04.0 3
A -0 6.04.0 4
S ee N o te 2 ab o ve
P erfo rm
IN ITIA L
T a n k In sp e ctio n
S e n d In itia l In sp e ctio n
R e po rt to TT O /1 3 ,
A sse t & C a mp a ig n
R e vie w R e p o rt
C a ll for S p e cia list
In sp e ctio n
If R e q u ire d
R eco m m e n d
C o rrective A ctio n
A sse t & C a m pa ig n
In struct
P ro je ct / C a m p a ig n
T o E xe cu te W ork
IN S P E C T O R
IN S P E C T O R
U E C /1 5 & U E C /15 x
U E C /1 5 & U E C /1 5 x
U E C /1 5 & U E C /1 5 x
A sse t T e a m
P re pa re
S co p e o f W o rk
As s o c iated S co p e:
In s p ec tio n S co p e:
O th er m aintena nce activity sh ou ld
b e tackled at the sam e tim e.
T ypically:
Instrum entation
V alve O verha uls
In itial :
Interna l V isua l + N D E to de term in e interna l cond itio n o f T a nk
In te rm e d iate :
T o ensu re tha t the initial req uire m e nts are be in g co rrectly de livere d
F in al:
T o ensu re tha t all rem edial w ork h as b ee n p erform ed to the corre ct qu ality
b efore ‘B ox-U p ’
M a in ten a nce P ro gra m m e / P la n
C o-o rdin atio n of M ainten an ce A ctivities
M a na ge m e nt of S A P
D evelopm en t & M ain te na nce o f M ainte n a nce P ro ce du res
C lo se-ou t of In spe ction & M a in te na n ce A ctio ns & R eco m m e nda tion s
E q uipm en t C e rtification
C he cking C orro sio n C o up on s
R o utin e M a inte na nce & S pe cific Insp ection s of T an ks, B u nd s & A ssocia te d E qu ipm en t
R o utin e & S pe cific M ainten an ce o f T a nks, B un ds & A ssociated E q uip m e nt
A ctivities Insid e T a nks / O n T a nks
R o utin e M a inte na nce & S pe cific Insp ection of P rocess E qu ip m en t & V alves
R o utin e & S pe cific M ainten an ce o f P roce ss E q uipm en t & V alves
T estin g o f P roce ss E q uipm e nt & V a lves
R o utin e M a inte na nce & S pe cific Insp ection of A la rm a nd T rip Instrum en ta tio n
R o utin e & S pe cific M ainten an ce o f A larm and T rip In strum en tatio n
T es tin g o f In strum en t T rips & A larm s
C o ntrol of O verrides
P ro je ct /M a in te n a n ce
M o b ilise R e so u rce s
C o m m e n ce
S co p e o f W o rk
C o m p le te
S co p e o f W o rk
B o x-u p T a n k
R e po rt & C lo se -o u t
W O In S A P
P ro je ct /M a in te n a n ce
P ro je ct /M a in te n a n ce
P ro je ct /M a in te n an ce
P ro je ct /M a in te n a nce
O X O /1 x
SAP
END
R e tu rn T a n k
T o S e rvice
P erfo rm
IN T E R M E D IA T E
T a n k In sp e ction
Issu e In term e d ia te
T a n k In spe ctio n
R e po rt
R e vie w R e p o rt
A d vise
P ro je ct / C a m p a ig n
A s n e ce ssa ry
IN S P E C T O R
IN S P E C T O R
U E C /1 5 x
U E C /1 5 x
O X O /1 x
S e e N o te 3 b elow
P erfo rm
F IN A L
T a n k In sp e ction
Issu e Fin a l
T a n k In spe ctio n
R e p ort
R evie w R ep o rt
Issu e N o tifica tio n
T o B o x-u p T a nk
D e te rmin e
N e xt In spe ctio n
D u e D a te
E n ter N e xt Insp e ctio n
D u e D a te
In to S A P
IN S P E C T O R
IN S P E C T O R
U E C /1 5 x
U E C /1 5 xx
U E C /1 5 x
U E C /1 5 x
P E TR O L E UM D E V E L O P M E N T O M AN
M usca t
L o c atio n o f
In s p ec tio n File s:
F ile R e p o rt
in A sse t
L o ca tio n
U E C /1 5 x
S T AR T
PR-1013
N o te : N D E
R oof
S h e ll
N o zzles
F lo o r
1
E xtern al
Ac c e s s
SAP
S e e N o te
P re p a re
T a n k In sp e ctio n
L o g istics
OND
OSD
MAF
F ahu d
M arm u l
C oast
T echniques
UT
UT
UT
A co u stic E m issio n
MFL
31/05/2005
A g re e
R e vie w T a n k
R e vie w T a n k
P e rfo rm
L o ca tio n
IN T E R IO R
U E O D F u nctio n
T an k In tern al In sp ectio n
COAST
N o / M in o r
An o m aly
C o n firm
N e xt In sp e ctio n
D u e D a te
E XT E R N A L
RIn
evisio
: n1 File s
s p e cntio
n s:
P rod uce d L
Bo
y catio
: UOM
OND
OSD
MAF
D a te : A p ril 200 4
D wg . N o : S E 5 a(i)
Fahud
M a rm u l
C o a st
F ile R e p o rt
in A sse t
L o ca tio n
U E C /1 5 x
S e e N o te ab ove
U E C /1 5 & U E C /1 5 x
A sse t M a in t T e a m
S ta tic E q u ip m e n t
N o te 3 :
T he ba ses used fo r the determ ination
A re E E M U A 1 59 an d A P I 65 0
S e n d In sp e ctio n
Version 3.0
Static Equipment Inspection & Maintenance Procedure
9 0 D P la n
Asset Team
PR-1013
STAR T
N o te 1 :
S o m e V e s s e ls re q u ire S ta tio n
S /D
b e c a u s e th e y a re tie d in to F la re
H eader
2
SAP
S e e N o te 1 a b o v e
31/05/2005
M o b ilis e
In s p e c to r
R e v ie w V e ss e l
In s p e c tio n F ile
U E C /1 5 x
IN S P E C T O R
In s p e c tio n F ile C o n ta in s :
E q u ip m e n t D ra w in g s
V e n d o r d a ta
O rig in a l M a te ria ls C e rtific a te s
‘R e n e w a b le ’ T e s t C e rtific a te s
P re v io u s In s p e c tio n & M a in te n a n c e R e p o rts
T h is is a n In v a s iv e p ro c e s s re q u irin g M a n E n try
Static Equipment Inspection & Maintenance Procedure
Version 3.0
S TAR T
No / M inor
Anom aly
E xternal
Access
SAP
Confirm
Next Inspection
Due Date
S ee Note
Prepare
Vessel Inspection
Logistics
PR-1013
Inspection Files
Locations:
O ND
OS D
MAF
Fahud
M arm ul
Coast
File Report
in Asset
Location
UEC/15x
UEC/15 & UEC/15 x
3
Asset Maint T eam
31/05/2005
Static Equipment
Inspection
Agree
14D Schedule
W ith O XO/xx
Review Vessel
Inspection File
Revie w Vessel
Inspection File
Perform
EXTERNA L
Vessel Inspection
Send Inspection
Report to TTO/13
Review Report
Enter
Inspection Data
Into PACER
UEC/15
Area Planner
UEC/15x
INSPECTO R
INSPECTO R
INSPECTO R
UEC/15 & UE C/15x
UEC/15 & UEC/15x
M ajor
Anom aly
M obilise
NDE Contractor(s)
Report & Close-out
W O In SAP
O XO /1x
Assess Need
SAP
E ND
Version 3.0
Static Equipment Inspection & Maintenance Procedure
S TAR T
No / M inor
Anom aly
E xternal
Access
SAP
Confirm
Next Inspection
Due Date
S ee Note
Prepare
Vessel Inspection
Logistics
PR-1013
Inspection Files
Locations:
O ND
OS D
MAF
Fahud
M arm ul
Coast
File Report
in Asset
Location
UEC/15x
UEC/15 & UEC/15 x
4
Asset Maint T eam
31/05/2005
Static Equipment
Inspection
Agree
14D Schedule
W ith O XO/xx
Review Vessel
Inspection File
Revie w Vessel
Inspection File
Perform
EXTERNA L
Vessel Inspection
Send Inspection
Report to TTO/13
Review Report
Enter
Inspection Data
Into PACER
UEC/15
Area Planner
UEC/15x
INSPECTO R
INSPECTO R
INSPECTO R
UEC/15 & UE C/15x
UEC/15 & UEC/15x
M ajor
Anom aly
M obilise
NDE Contractor(s)
Report & Close-out
W O In SAP
O XO /1x
Assess Need
SAP
E ND
Static Equipment Inspection & Maintenance Procedure
9 0 D P la n
Version 3.0
N o te 1 :
S o m e F ire d H e a te rs m a y re q u ire
S ta tio n S /D
Asset T eam
N o te 2 :
T y p ic a lly fo r R e fra c to ry a s s e s s m en t
STAR T
SAP
M o b ilis e
F H In s p e c to r
R e v ie w
In s p e c tio n F ile
U E C /1 5 x
IN S P E C T O R
In s p e c tio n F ile C o n ta in s :
E q u ip m e n t D ra w in g s
V e n d o r d a ta
O rig in a l M a te ria ls C e rtific a te s
‘R e n e w a b le ’ T e s t C e rtific a te s
P re v io u s In s p & M a in t R e p o rts
S e e N o te 1 a b o v e
PR-1013
5
31/05/2005
S ta tic E q u ip m e n t
In s p e c tio n
A g re e
1 4 D S c h e d u le
W ith O X O /xx
C o o l D o w n a n d D ra in
F ire d H e a te r
fo r In s p e c tio n
P h y s ic a lly
Is o la te U n it
F o r M a n E n try
O pen up
M a n d o o rs a n d
Access
Is s u e
C o n fin e d S p a c e
E n try P TW
U E C /1 5
A re a P la n n e r
S eOeX ON/1oxte
A s s e t M a in t T e a m
A s s e t M a in t T e a m
O X O /1 x
H S E -C ritic a l T a sk R e fe re n c e :
A -0 6 .0 1
A -0 6 .0 2
A -0 6 .0 3
A -0 6 .0 4
M a in te n a n c e P ro g ra m m e / P la n
C o -o rd in a tio n o f M a in te n a n c e A c tiv itie s
M anagem ent of S AP
D e v e lo p m e n t & M a in te n a n c e o f M a in te n a n c e P ro c e d u re s
Version 3.0
Static Equipment Inspection & Maintenance Procedure
S T AR T
SAP
O n g o in g Ro u tin e In sp ectio n o f O n -P lo t P ip ew o rk
PR-1013
P rovide
Inspection S e rvices
S ta tic E qu ipm ent
Insp ection
A gre e
14D S ched ule
W ith O X O /xx
U E C /1
U E C /15
A rea P lann er
6
S ee
M ap 5d (ii)
END
31/05/2005
B aselin e In sp ectio n o f N ew O n -P lo t P ip ew o rk
P ro
roject
ject
Static Equipment Inspection & Maintenance Procedure
Version 3.0
Inspection Files
Locations:
Ongoing Routine Inspection of On-Plot Pipework
OND
OSD
MAF
No / Minor
Anomaly
START
Fahud
Marmul
Coast
Access
SAP
Prepare Inspection
Logistics
PR-1013
UEC/15x
UEC/15 & UEC/15x
7
31/05/2005
Asset Maint Team
Provide
Inspection Services
Static Equipment
Inspection
Agree
14D Schedule
With OXO/xx
Review
Inspection File
Perform
EXTERNAL
Piping Inspection
Send Inspection
Report to TTO/13
Review Report
Enter
Inspection Data
Into PACER
UEC/1
UEC/15
Area Planner
INSPECTOR
INSPECTOR
INSPECTOR
UEC/15 & UEC/15x
UEC/15 & UEC/15x
Mobilise
NDE Contractor
File Report
in Asset
Location
Confirm
Next Inspection
Due Date
See Note
External Inspection Scope:
Major
Anomaly
Report & Close-out
WO In SAP
OXO/1x
SAP
END
Version 3.0
Static Equipment Inspection & Maintenance Procedure
Note:
Inspection Scope is 100% of
Bottom Pipe Segment Only.
START
SAP
See Note
Provide
Inspection Services
Static Equipment
Inspection
Plan the
Flowline Inspections
UEC/1
UEC/15
UEC/15x
PR-1013
Prepare & Issue
List of Flowlines
For Inspection
Asset Team
8
Mobilise
Inspection
Contractor
Scan Pipe run
Using
External MFL Tool
Map defect Areas
Using
UT
UEC/15x
INSPECTOR
INSPECTOR
Issue
Report of Findings
To TTO/13x
Assess
Inspection Findings
INSPECTOR
Integrity Eng
31/05/2005
Enter
Inspection Data
Into PACER
Inspection Files
Locations:
OND
OSD
MAF
Fahud
Marmul
Coast
File Report
in Asset
Location
Static Equipment Inspection & Maintenance Procedure
Version 3.0
STAR T
SAP
M itig a tio n
PR-1013
M o n ito rin g
C o rro s io n
C o n tro l
C a th o d ic
P ro te c tio n
CP
Q u a rte rly
M o n ito rin g
M e a s u re O N P o te n tia l
a t E v e ry C P P o te n tia l
T e s tin g L o c a tio n
C o n tra cto r
C o n tra c to r
C o n tra c to r
C o n tra c to r
9
C o n tro l
M e a s u re G ro u n d b e d
P o te n tia l
R e c o rd
M e a s u re m e n ts
In P A C E R
C o n tra c to r
C o n tra c to r
P re p a re
Q u a rte rly R e p o rts
A n d D e fic ie n c y L ist
R e v ie w a n d
A n a ly s e R e p o rt
C o n tra cto r
C o rr E n g
31/05/2005
C o n firm
J o b C o m p le te
Version 3.0
Static Equipment Inspection & Maintenance Procedure
SAP
S T AR T
C IP S /D C V G
P ro v id e
Y e a rly P la n
P la c e
W ork O rd e r
C o n tra c to r
C o rro s io n E n g
C o rro s io n E n g
S c h e d u le
W ork L o a d
PR-1013
C o n tra c to r
10
31/05/2005
N o m in a te
S u b -C o n tra c to r
S u b m it
P ro c e d u re s
F o r A p p ro v al
C o n tra c to r
SUB CON
Static Equipment Inspection & Maintenance Procedure
START
Version 3.0
Monitor
QA/QC Deliverables
SAP
UEC/11
Static Equipment Repair
Recommended by TTO/13x
Provide
Inspection Services
UEC/1
PR-1013
Static Equipment
Inspection
Prepare
Scope of Work
Review SOW
And Produce
QA/QC Plan
Mobilise
Labour & Equipment
Resources Required
Commence
Scope of Work
Perform
INTERMEDIATE
Inspection
Complete
Scope of Work
Perform
FINAL
Inspection
Issue Notification
To Box-up
Box-up
Equipment
Report & Close-out
WO In SAP
UEC/15
Project /Maintenance
UEC/15x
UEC/11
Project /Maintenance
Project /Maintenance
INSPECTOR
Project /Maintenance
INSPECTOR
UEC/15x
Project /Maintenance
OXO/1x
11
Mobilise Material
Resources Required
Project /Maintenance
The Scope of Work would include the necessary
Proof tests required for the item of equipment
concerned. ‘Renewable’ test certificates would
need to be updated as necessary
31/05/2005
Enter Next Inspection
Due Date
Into SAP
Return Equipment
To Service
UEC/15x
OXO/1x
File Report
SAP
END
Version 3.0
Static Equipment Inspection & Maintenance Procedure
Note 1:
High Criticality Duty
Maintenance Strategy / Repair Philosophy m ay require “Modular
Change-out” of RV with Spare Unit already Tested & Certified.
90D Plan
Asset Team
Note 2:
Record the local condition as-rem oved. In particular if RV Seal still
intact (Integrity Issue)
STAR T
SAP
See Note 1
See Note 2
Provide
Inspection Services
RV
Re-Certification
Agree
14D Schedule
W ith O XO/xx
Prepare
Parent Tag
For RV Change-out
M odular
C hange-out
RV
R eturn
Parent Tag
To Service
Report & Close-out
W O In SAP
UEC /1
U EC/15
PDO Planner
O XO /1 Team
M aintenance
O XO /1 Team
OXO /1x
PR-1013
12
SAP
Inspection Files
Locations:
END
O ND
O SD
MAF
31/05/2005
Fahud
Marm ul
Coast
Update
SAP
U pdate Register
Of
Relief D evices
File R eport
in Asset
Location
U EC/15 & UEC/15 x
UEC/15 & U EC/15 x
UEC/15 x
Static Equipment Inspection & Maintenance Procedure
Version 3.0
Inspection Files
Locations:
Note1:
START
SAP
Movable Equipm ent
Mobile Equipment
Fixed Equipm ent
Chain Blocks
Chains and Chain Slings
Ropes and Rope Slings
Geared Beam Trolleys
Clam ps
Shackles & Pins
Telescopic Crane
Hyab
Fork Lift Trucks
A-Fram es
Gantry Cranes
Hoists
Fixed Lifting Devices
OND
OSD
MAF
Fahud
Marm ul
Coast
File Report
in Asset
Location
UEC/15x
Provide
Inspection Services
UEC/1
PR-1013
Lifting Equipment
Re-Certification
UEC/15
Agree
14D Schedule
W ith OXO/xx
PDO Planner
Collect Movable
Lifting Equipment
To Inspection Area
PDO Team
Prepare Fixed
Lifting Equipment
For in-situ Inspection
13
See Note 3
See Note 2a
See Note 1
Perform
Lifting Equipment
Inspection
INSPECTOR
Quarantine Items for
Refurbishment
(Or Destruction)
INSPECTOR
Raise W O for
Refurbishment of
Quarantined Items
PDO Team
Re-Certify
Good
Lifting Equipment
Colour Code
Re-Certified
Lifting Equipment
Confirm
Next Inspection
Due Date
Return
Lifting Equipment
To Service
Report & Close-out
W O In SAP
INSPECTOR
PDO Team
INSPECTOR
PDO Team
OXO/1x
Update Register
Of
Lifting Equipment
31/05/2005
UEC/15 & UEC/15x
PDO Team
Note 3:
Refurbish
Defective Items
Industry standard is to Colour Code Lifting Equipm ent items to show
users that they are within current certification and not overdue
SAP
END
Version 3.0
PR-1013
Static Equipment Inspection & Maintenance Procedure
14
31/05/2005