Saep 1624

Engineering Procedure
SAEP-1161 26 March 2015

Testing and Inspection (T&I) Reporting Procedure
Document Responsibility: Inspection Engineering Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope................................................................ 2
2 Purpose............................................................. 2
3 Conflicts and Deviations……………………...…. 2
4 Applicable Documents....................................... 3
5 Definitions and Abbreviations............................ 4
6 Instructions……………………………………….. 6
7 Responsibilities................................................ 12
Appendix A - Sample Report Form Layout and References................. 16

Appendix B - Sample Post T&I Report Form Layout and References... 18
Appendix C - Fired Heater Inspection Results Information.................... 20
Appendix D - Heat Exchanger Inspection Results Information............. 21
Appendix E - Pressure Vessel Inspection Results Information............. 23
Appendix F - Critical Input Data............................................................ 24
Appendix G - Tank Data Recording Requirements............................... 25
Previous Issue: 15 March 2010 Next Planned Update: 26 March 2020
Primary contacts: (1) Kakpovbia, Anthony Eyankwiere (kakpovte) on +966-13-8801772

(2) Abdulcader, Seyed Mohammed (seyedam) on +966-13-8801778
Copyright©Saudi Aramco 2015. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-1161
Issue Date: 26 March 2015
Next Planned Update: 26 March 2020 Testing and Inspection (T&I) Reporting Procedure
1 Scope
This Saudi Aramco Engineering Procedure provides,
1.1 Minimum requirements for reporting inspection findings during Testing and
Inspection (T&I).
1.2 Minimum technical content for the pre-T&I, post-T&I and the Summary report
covering the pre- and post- T&I activities.
1.3 Mandate for a minimum of four reports namely Pre-T&I Report, Post-T&I
Report, T&I Summary Report and Repair Data Report.
2 Purpose
This SAEP provides a summary of minimum requirements for T&I reporting for
operating facilities to ensure:
2.1 Critical inspection information is documented and available for pre-, during, and
post- T&I work.
2.2 Critical inspection findings are recorded and reported in a consistent format for
planning and execution.
2.3 Documents are properly organized, controlled, safely stored, trackable and
retrievable in a manner consistent with the intent of 00-SAIP-78.
2.4 Reporting requirements are specified and standardized companywide for all
phases of the reporting period.
3 Conflicts and Deviations
3.1 Conflicts
Any conflicts between this procedure and other applicable Saudi Aramco
Engineering Procedures (SAEP's), Saudi Aramco Engineering Standards
(SAES's), Materials System Specifications (SAMSS's), Standard Drawings
(SASD's), or industry standards, codes, and forms shall be resolved in writing by
the Company or Buyer Representative through the Chairman, Inspection
Engineering Standards Committee of Saudi Aramco.
3.2 Deviations and Waivers
Direct all requests to deviate or waive the requirements of this Procedure in

writing according to the internal company procedure SAEP-302, Instructions for
Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.
Page 2 of 25
4 Applicable Documents
The requirements contained in the following documents apply to the extent specified in
this procedure:
 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-22 Tank Calibration Requirements
SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-317 Testing and Inspection (T&I) of Shell and Tube
Heat Exchangers
SAEP-319 Pressure Relief Devices - Testing and Inspection
Requirements
SAEP-325 Inspection of Pressurized Equipment
SAEP-343 Risk Based Inspection
SAEP-1025 Chemical Cleaning of Boilers
SAEP-1135 On-Stream Inspection Administration
Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-D-008 Repairs, Alterations, and Re-rating of Process
Equipment
SAES-D-108 Repairs, Alterations, and Reconstruction of Storage
Tanks
Saudi Aramco Inspection Procedures

00-SAIP-75 External Visual Inspection Procedure
00-SAIP-76 Worksheet Control and Tracking
00-SAIP-77 Technical Alert Implementation and Tracking
Program
00-SAIP-78 Inspection Records/Filing Procedure
00-SAIP-80 Guidelines for Process Equipment Inspection
Page 3 of 25
Saudi Aramco General Instructions

GI-0002.600 (SA-7180) Plant/Unit Acceptance after T&I Shutdown
Saudi Aramco Forms, Data Sheets and Miscellaneous

SA-3060-ENG T&I Acceptance Report
SA-2093-ENG Equipment Inspection Record
SA-2643-ENG Worksheet (Defect Notification)
SA-2699-ENG Unfired pressure Vessel External Inspection Report
SA-2760-ENG Approval Request to deviate from Equipment
Inspection Schedule
5 Definitions and Abbreviations
Defect Notification: Defect notification is a document issued to operations for

remediation of an inspection finding that requires corrective action. The defect
notification may apply to equipment, piping, civil, electrical or miscellaneous
components to enhance integrity of the item for reliable and safe operation of the
facility. Saudi Aramco Form SA-2643-ENG is currently being used to document
Defect notification. The Defect notification could be paper based or electronic
depending upon the Defect notification tracking system.
Defect Notification Tracking System: System developed by the Saudi Aramco

OIU Facility or by Inspection Department to track the progress of Defect notification.
The tracking system should have the capability to identify open or incomplete Defect
notification. A Defect notification module is available to OIUs for Defect notification
tracking in the SAP Application for Inspection of Facilities (SAIF) system.
Equipment Inspection Schedule (EIS): An approved record governed by SAEP-20

that documents inspection intervals and inspection procedures of initial and subsequent
T&Is and On Stream Inspection (OSI) for fixed equipment and piping systems.
I5 Notification: T&I Notification generated automatically by the SAIF system before

the equipment is due for T&I.
Inspector: An inspector / inspection engineer is an employee who is qualified to

perform inspection activities per the applicable Saudi Aramco Job Description.
Material Take Off List: List of materials identified for replacement at future T&I.
MAWP: Maximum Allowable Working Pressure
OIU: Operations Inspection Unit. Same as Plant Inspection Unit.
Page 4 of 25
PIU: Plant Inspection Unit in operating department. Same as Operations Inspection Unit.
SAIF: SAP Application for the inspection of facilities
Shutdown Memorandum: A package containing the shutdown related documents

prepared by the OIU to the T&I planning group (such as pre and post T&I reports,
scope of work, plant surveys, active worksheet, cathodic protection, civil, coating, and
any miscellaneous inspection data relating to shutdowns).
T&I Reports
a) Pre-T&I Report: A summary report generated by the Plant Inspection Unit
twelve (12) months before T&I that contains the details of the intended work to be
executed during T&I. The format of this report shall be as per requirements of this
procedure. This report shall be uploaded to SAIF system.
b) Post T&I Report: A detailed report describing the scope, extent and findings of
testing and inspection activities completed including all associated NDT reports
and recommendations. The format of this report shall be as per requirements of
this procedure. This report shall be uploaded to SAIF system.
c) T&I Summary Report: A summary report generated by the Plant Inspection Unit
after the T&I which contains brief detail of the work done during T&I, short note on
lessons learned in the whole cycle
(from pre-T&I to box-up) and recommendations for future T&I. A recommended
format of this report is outlined in this procedure however, other formats acceptable
to proponent management can be used for the Summary Report only. The format
used shall be uploaded to the SAIF system.
d) Repair Data Report: A detailed report describing the repair work done during
T&I. This report shall be uploaded to SAIF system.
T&I (Testing and Inspection): Testing and Inspection (T&I) is a scheduled, time-
based activity governed by an approved Equipment Inspection Schedule (EIS) for
shutting down an equipment for a pre-determined period, to execute pre-determined,
well-defined inspection and maintenance tasks. The main purpose of T&I is to ensure
and document the mechanical integrity, operability and safety of the covered equipment
for continued operation. The T&I activities are performed at intervals determined by
SAEP-20 “Equipment Inspection Schedule”. Every plant equipment that is included in
the EIS is subject to a scheduled T&I. The T&I can involve a single piece of
equipment, multiple equipment and/or total plant shutdown. In SAIF, this is
represented by the T&I number.
T&I Acceptance Report: T&I Acceptance Report (Form SA-3060-ENG) is a

report generated by the T&I acceptance committee formed as per the requirements of
GI-0002.600 for Plant/Unit Acceptance after T&I.
Page 5 of 25
T&I Number: A T&I package number that is generated by the SAIF system, which
can contain one or multiple T&I notification.
6 Instructions
6.1 Pre-T&I Report
6.1.1 OIU shall prepare pre T&I reports which shall include:
a) Equipment number
b) Inspection findings and recommendations from previous T&I
c) On-Stream Inspection (OSI) recommendations as per SAEP-1135
d) Pending Inspection Defect Notifications (previously Work Sheets as
per 00-SAIP-76)
e) Revamps /project proposals and recommendations.
6.1.2 The Pre-T&I Report shall be issued prior to T&I start date as required by
proponent department manager but not later than three (3) months prior,
in the absence of proponent management mandate; to:
a) Maintenance T&I planning
b) Operations division head
c) Maintenance division head (to be added as interested party for the
T&I notification (I5) in SAIF)
d) Engineering division head (shall be added as interested party for the
T&I notification (I5) in SAIF)
6.1.3 The Pre-T&I report shall contain all scheduled T&I in SAIF.
6.1.4 The Pre T&I planning shall be based upon the information obtained from:
a) Pending Defect Notifications (Work Sheets).
b) External inspection reports.
c) Previous T&I recommendations and material take off list.
d) On-Stream Inspection (OSI) records.
e) Risk Based Inspection (RBI) report recommendation – SAEP-343.
f) Leaks history.
g) Number of OSI (CML) locations at Tmin or below and corrosion
service class as per SAEP-1135.
Page 6 of 25
h) Cathodic Protection (CP) inspection reports recommendation.

i) Operational upsets history.
j) Technical Alerts as per 00-SAIP-77.
k) List of temporary repairs planned for upgrade to permanent repairs.
l) Requirement for chemical cleaning of Boilers as per SAEP-1025.
6.1.5 The contents of the Pre T&I report shall include but not limited to:
a) Facility and the plant description.
b) Processing unit description.
c) Details on individual equipment scheduled in the T&I
d) Details of the work flow for internal and external maintenance work
including the following requirements:-
i. Blinding equipment.
ii. Scaffolding requirements.
iii. Lighting requirements.
iv. Requirements for removal/addition of insulation.
v. Method(s) for cleaning, specifying the special requirements
based upon the normal contents of the equipment, material of
fabrication, future operation needs, internal attachment
details, etc.,
vi. Details of the internal attachments to be dismantled for
inspection and repair.
vii. Details of the repairs already known from the operation
history, inspection reports, previous T&I recommendations
and the pending worksheets.
viii. Welding procedures and details on consumables, if already
known.
ix. Details of the coating requirements, including the removal of
existing coating, type and extent of the blasting/cleaning
requirements, stating the appropriate coating type and
procedure.
x. Details of the expected repairs based upon previous
experience and the operational history of the equipment.
xi. Inspection Test Plans showing planned inspection hold points
during the opening, dismantling of the internal attachments,
Page 7 of 25
cleaning, and during the planned repairs work.

xii. Repair Package - the Engineering Unit responsible for design
packages in proponent organization shall be responsible for
developing any required repair package. Inspection hold
points for unplanned repair work identified following
inspection shall be defined in the repair plan.
xiii. List of design package details including number and
description prepared by the Engineering Unit responsible for
design packages in proponent organization.
xiv. Details of the external civil work based on pending worksheets.
xv. Details of the refractory repair requirement (if applicable),
specify the type of the refractory and appropriate method of
application.
xvi. Details of the required electrical work for the internal and
external components.
xvii. Details of the post repair & inspection cleanup.
xviii. Preparing the equipment for closure and de-binding
requirements.
xix. Scaffolding and Cleaning for conventional and advanced
NDT.
xx. List the equipment that requires refractory removal and
insulation removal for NDT.
xxi. MOC requirements and approval plan.
xxii. Applicable reporting forms as attached to this procedure.
xxiii. Facilities with storage tanks used for Royalty/Custody
measurement shall develop appropriate tanks calibration
procedure and reporting requirements to comply with
SAEP-22 mandates for such equipment.
xxiv. Plan for chemical cleaning of Boilers as per SAEP-1025
requirement.
6.2 Post T&I Report
6.2.1 All reports shall have the following information on the front page, as
applicable:
a) Report number and date prepared
b) Equipment No. & Service, Location/Area, Plant No.
Page 8 of 25
c) Reason for inspection and date inspected

d) Plant & Equipment (P&E) Inspector, Field Inspection Supervisor and
Unit Supervisor
e) Equipment Data:
i. Material and clad/overlays
ii. Design: pressure
iii. Temperature
iv. Thickness & Corrosion Allowance (CA)
6.2.2 Report Layout shall have continued pages and contain:

a) Summary (in less than 150 words)
b) Findings: (Size and Location)
i. External
ii. Internal
c) Repairs/Renewal - Record of repairs, re-rating and alterations
attached to SAES-D-008 fully completed as applicable.
d) Records of Tests performed - NDT, scales/samples, etc., pressure
testing (hydrostatic or pneumatic test) and test conditions.
e) Waivers approved according to GI-0002.600.
f) Photograph/Video numbering, where allowed and applicable.
g) Page Numbers.
6.2.3 The inspection reports shall be drafted by the assigned inspector;

reviewed by the area inspection field supervisor and approved by the
OIU Supervisor.
6.2.4 The Post T&I Report shall include, as-found condition, defect/damage
mechanisms found, repairs completed (partial and/or full repairs) and
recommendations for the future such as:
a) Full details of any repairs or renewals which were carried out and
forecast probable repairs or renewals which will be required at the
next inspection.
b) Areas not accessible for inspection and reasons why.
c) Details on inspection techniques used, including procedures where
appropriate and areas inspected.
Page 9 of 25
d) Date of the next internal inspection, together with any special

inspection requirements, materials or specific components which
may be required during the next T&I.
e) Any change in the Equipment Inspection Schedule with indication of
the justification as applicable.
f) Chemical cleaning report
i. Records of any chemical cleaning of Boilers completed as per
SAEP-1025 requirement.
ii. Recommendations and schedule for future chemical cleaning
of boilers.
g) Attach all relevant Saudi Aramco Forms where applicable including:
SA-3060-ENG T&I Acceptance Report
SA-6717-ENG Request for Inspection
SA-2093-ENG Equipment Inspection record
SA-2643-ENG Worksheet
SA-2699-ENG Unfired pressure Vessel External Inspection
Report
SA-2760-ENG Approval Request to deviate from Equipment
Inspection Schedule
6.2.5 Facilities with storage tanks used for Royalty/Custody measurement

shall submit the completed calibration report and the capacity tables
generated to the Operations Division head for compliance with SAEP-22
requirements.
6.3 T&I Summary Report
6.3.1 Shall include an executive summary, brief highlight of the

equipment/piping findings and recommendations, lessons learned during
the pre- to post-T&I work activities, the major activities to be considered
in planning for the next T&I, material take-off list, EIS revision
requirements, process improvement recommendations, etc.
6.3.2 Shall summarize all of the work done during the T&I, and the
recommendations for the next T&I. The specification and other
descriptive details of each piece of static equipment inspected in the T&I
will be separately tabulated.
6.3.3 T&I summary report shall be issued by OIU Supervisor within 60 days
after completion of the T&I.
Page 10 of 25
6.3.4 The contents of the Post T&I Summary report shall include but not
limited to:
a) Plant number and name.
b) Processing unit description.
c) Details for each of the individual pieces of static equipment involved
in the T&I.
d) Brief summary of inspection activities performed on individual
pieces of static equipment and piping during the T&I.
e) Summary of the repair work performed on individual pieces of static
equipment and piping involved in the T&I.
f) The recommendations for the next T&I, including the list of
temporary repairs performed or deferred until the next T&I.
g) Material take-off list.
h) Process improvement recommendations.
6.4 Maintaining Inspection Reports
6.4.1 Record of the inspection activities for each equipment shall be

maintained in a retrievable format in SAIF.
6.4.2 Maintain marked drawings (P & IDs, isometrics, schematics, etc.)

relevant to the inspection, with areas susceptible to process related
deterioration mechanisms highlighted.
6.4.3 Relevant updated isometrics showing inspection locations shall be

developed and maintained within 12 months of completion of the T&I.
6.4.4 Technical correspondence relevant to equipment inspected shall be

maintained in equipment file.
6.4.5 SISs of the equipment shall be updated if necessary and maintained.
6.4.6 Boilers chemical cleaning records shall be maintained in a format which

meets SAEP-1025 requirements.
6.4.7 Data, sketches and diagrams relevant to the T&I including findings and
defects which are covered in the following appendices, shall be
maintained:
a) Appendix A: list the defect types and the data required to evaluate
and size each defect.
Page 11 of 25
b) Appendix B: list the Basic Data Record Forms required for each
equipment and shall be updated after each T&I inspection.
c) Appendix C: Fired Heater Inspection Results Information
d) Appendix D: Heat Exchanger Inspection Results Information
e) Appendix E: Pressure Vessel Inspection Results Information
f) Appendix F: Critical Input Data
g) Appendix G: Tank Data Recording Requirements
6.4.8 Appendices C to F contain Tables which documents the data required to

evaluate the integrity of the inspected equipment.
6.5 SAIF Utilization
6.5.1 Report formats available in SAIF shall be used to comply with the
requirements of this procedure with the exception of the T&I Summary
Report.
6.5.2 Quality of T&I data uploaded into SAIF shall be validated by a reviewer
assigned by OIU Supervisor.
7 Responsibilities
7.1 Supervisor, Operation Inspection Unit shall:
7.1.1 Review, approve and issue the reports mentioned in the Scope,
including:
a) Pre-T&I Report to Superintendent, Operations, prior to T&I start
date.
b) Post T&I Report to Superintendent, Engineering within 45 days of
T&I completion date with a copy to the division heads of Operations
and Maintenance as well as T&I Planning Unit Supervisor. A copy
of relevant sections shall be saved in each equipment file.
c) T&I Summary Report to Superintendent, Operations, not later than
60 days after completion of T&I date. The report shall include an
executive summary, T&I recommendations, listing of any materials
identified for replacement at future T&I (material take off list) and a
summary of findings for each single equipment inspected. A copy of
this report shall be sent to the division heads of Maintenance and
Engineering as well as T&I Planning Unit Supervisor.
Page 12 of 25
7.1.2 Assign individuals or a team that will record and validate the inspection
activities for each equipment in a retrievable format in SAIF.
7.1.3 Ensure that adequate, detailed and auditable inspection reports of all
items of equipment requiring inspection are maintained. All Inspection
reports shall be formally reported and the reports placed in the
equipment file.
7.1.4 Alert proponent management of any significant events or any changes

that may affect the safety or operational efficiency of inspected
equipment, and the need for remedial actions.
7.1.5 Establish and revise inspection reports, forms and records to comply
with relevant requirements of applicable Saudi Aramco standards and
procedures.
7.1.6 Assign a reviewer to validate quality of T&I data uploaded in SAIF.
7.1.7 Approve the Pre-T&I and Post-T&I reports in SAIF.
7.2 Field Supervisor, Operation Inspection Unit, shall:
7.2.1 Review the equipment inspection final report, T&I recommendations,

material take off list and prepare the T&I summary report for the review
of the unit supervisor within 21 days of the T&I completion.
7.2.2 Complete approvals in SAIF as required.
7.3 Inspector, Operation Inspection Unit, shall:
7.3.1 Maintain records of each inspection activity for each equipment, in a

retrievable manner to include as a minimum:
a) Marked drawings (P & IDs, isometrics, schematics, etc.) relevant to
the inspection, with areas susceptible to process related deterioration
mechanisms highlighted.
b) Relevant isometrics showing inspection locations.
c) Relevant correspondence to equipment inspected.
d) SISs of the equipment.
7.3.2 Document all reports and tests/examinations results including pressure

tests and reflect in SAIF.
7.3.3 Maintain a permanent and progressive set of records (e.g., Eddy Current,
Magnetic Flux Leakage, Acoustic Emission, IRIS reports, etc.) for each
Page 13 of 25
piece of equipment and upload in SAIF.
7.3.4 Document corrective actions taken to address non-conforming items

resulting from inspections, examinations and tests and upload in SAIF.
7.3.5 Create a T&I number and package for each notifications under it in
SAIF. Package may be for one or a combination of Notifications.
7.3.6 Compile the equipment inspection final report, T&I recommendation for
equipment, material take-off list for the review and approval for the Field
Supervisor within 7 days of the T&I completion.
7.4 NDT Coordinator, shall:
Compile all NDT reports and submit to the responsible P&E inspector for
compiling the inspection final reports within 3 days of the T&I completion.
7.5 Supervisor, Engineering Unit responsible for design packages in proponent

organization shall:
7.5.1 Provide revamps/project proposals and recommendations for the

Pre-T&I Report.
7.5.2 Assign engineer or team that will be responsible for developing any
required repair package. Inspection hold points shall be defined in any
repair plan provided.
7.5.3 Review the following and provide recommendations for Pre-T&I Report.
a) List of temporary repairs planned for upgrade to permanent repairs
b) OSI (CML) locations at Tmin or below.
c) List of Technical Alerts awaiting action.
d) Cathodic Protection (CP) inspection reports recommendation.
e) Operational upsets history.
f) Previous T&I recommendations and material take off list.
g) On-Stream Inspection (OSI) records.
h) Risk Based Inspection (RBI) report recommendation.
i) Leaks history.
7.5.4 Provide list and description of design packages prepared by the

Engineering Unit responsible for design packages in proponent
organization for inclusion in the Pre-T&I Report.
Page 14 of 25
Revision Summary
26 March 2015 Major Revision.
Revised the "Next Planned Update" and reaffirmed the content of the document.
Validated content of forms in procedure.
Re-arrange content according to SAEP-134.
Referenced SAIF as required for data management.
Added tanks calibration reporting requirement to comply with GI-0405.001 and GI-0405.007
and SAEP-22 mandates for storage tanks used for Royalty/custody measurement.
Page 15 of 25
Appendix A – Defect Documentation (Internal / External)
DEFECT TYPE INFO. REQUIRED FOR EVALUATION

Internal Defects
Fouling 1. Location and description

2. Sketch affected area
3. Estimated Quantity
4. Particulate size of foulant
General and Localized Pitting 1. Location and description
Corrosion 2. Sketch defective area
3. Measurement area and depth of corrosion
4. Measurement average/max. pit depth & separation
Weld Root Corrosion 1. Location and description
2. Intermittent or continuous
3. Length/thickness around weld
4. Inspection method
Cracking 1. Location and description

2. Sketch defective area
3. Nature of crack (e.g. branching)
4. Dimensions
Inclusions (plate or weld) 1. Location and description

3. Dimensions (size and depth)
Laminations (plate) 1. Location and description

3. Dimensions (size and depth)
Low Wall Thickness 1. Location and description

3. Dimensions of area of thinning
Variation from Design Specification 1. Location and description
2. Sketch of variation
3. Extent of variation
External Defects
General Surface Corrosion 1. Location and description

3. Measurement/estimate area of corrosion
4. % area covered
5. Measurement average/max. pit depth & separation (if pitting present)
Page 16 of 25
Pitting Surface Corrosion 1. Location and description

3. Measurement/estimate area of corrosion
4. % area cover
5. Measurement average/max. pit depth & separation
Part Misaligned 1. Location and description

2. Sketch defect area
Physical Damage 1. Location and description
3. Dimensions of physical damage (length, width and depth)
Surface Cracks 1. Location and description

3. Nature of crack (e.g. branching)
4. Dimensions
Defective Coating 1. Location and description

3. Dimensions of coating damage
4. Approximate % of bare metal
5. Approximate % of primer
6. Approximate % of top coat
Part Loose 1. Location and description

2. Sketch of part and location
Part Missing 1. Location and description

2. Sketch of part and location
Variation from Design Specification 1. Location and description

2. Sketch of variation
3. Extent of variation
Page 17 of 25
Appendix B – Sample Post T&I Report Form Layout and Referencesa
INSPECTION FINAL REPORT FOR VESSELS

Report No.: Date prepared:
Equipment No. & Service Location/ Area: Plant No.:

Reason for Inspection: Date Inspected
P&E Inspector: Field insp. Supervisor: Unit Supervisor :
Equipment data:
Shell Material: Design Pressure, Kg/ cm²g or psig:
Shell thickness (mm/ in) Design Temp. °C or °F:
Cladding/ Lining (mm/ in) Corrosion Allowance (mm or in)
SUMMARY:
Commentary Note: include major highlights within 150 words
FINDINGS: SIZE and LOCATION:

External:
Commentary Note: Equipment external condition, leaks, painting/insulation, etc.
Internal:
Commentary Note: This section highlights internal condition, attachment such as tray, supports, bolts etc.
REPAIRS/RENEWAL:
Commentary Note: type of repair, material, PMI PWHT, etc.
TESTS:
Commentary Note: Scale sample test report, PMI, Insitu Metallography, etc.
NDT:
Commentary Note: UT, PT, RT, HT WFMPI, etc.
Hydrostatic:
Commentary Note type of test, waiver
RECOMMENDATIONS:
Commentary Note: Highlight required action for the future in bullet form
a
References
1. SAES-A-004 General requirement for pressure testing
2. SAES-D-008 Repair, Alteration, Re rating of process equipment
3. SAEP-20 Equipment Inspection Schedule
4. SAEP-317 Testing and Inspection of shell and tube heat exchangers
5. SAEP-325 Inspection requirement for pressurized equipment
Page 18 of 25
6. 00-SAIP-75 External Visual Inspection Procedure

7. 00-SAIP-80 Inspection Guidelines
8. API 510 Pressure Vessel Inspection code
9. API RP 572 Inspection of Pressure Vessel
10. API RP 573 Boiler & Heater Inspection
11. DP-Dye penetrant
12. UT-Ultrasonic Testing
13. RT-Radiographic Test
14. MPI-Magnetic Particle Test
15. MFL-Magnetic flux Leak Test
16. ET- Eddy Current Test
17. WFMPI-Wet Florescent Magnetic Particle Test
Page 19 of 25
Appendix C – Fired Heater Inspection Results Information
C.1 General Inspection Data

C.1.a Inspection Date
C.1.b Inspection Type (On or Off-Stream)
C.1.c NDT Methods Used (Text)
C.1.d Nameplate Details Checked (Y/N)
C.1.e Minimum Head Thickness (in)
C.1.f Minimum Shell Thickness (in)
C.1.g Inspection Findings (Text)
C.2 Internal Inspection Data (Head/Shell)

C.2.a Condition of Internal Components (Text)
C.2.b Service Related Cracking Detected (Y/N)
C.2.c Maximum Shell Pit Depth (in)
C.2.d Maximum Head Pit Depth (in)
C.2.e Maximum Tube Internal Pit Depth (in)
C.2.f Maximum Tube External Pit Depth (in)
C.2.g Description of Pit Sizes and Locations (Text)
C.3 Recommended Follow-up Actions

C.3.a C&I Recommended New Grade
C.3.b C&I Recommended Next External Inspection Frequency
C.3.c C&I Recommended Next Internal Inspection Frequency
C.3.d External Paint Requires Repainting (Y/N)
C.3.e Recommended Weld or Other Repairs (Text)
C.3.f Summary of Follow-up Actions Performed and Dates (Text)
C.4 Calculated Results Based on Inspection Information

C.4.a Minimum Allowable Wall Thickness (MAWT) of Shell
C.4.b Minimum Allowable Wall Thickness (MAWT) of Head
C.4.c Shell Short Term General Corrosion Rate
C.4.d Tubing Short Term General Corrosion Rate
C.4.e Head Short Term General Corrosion Rate
C.4.f Shell Long Term General Corrosion Rate
C.4.g Tubing Long Term General Corrosion Rate
C.4.h Head Long Term General Corrosion Rate
C.4.i Worst Case Corrosion Rate
C.4.j Estimated Thickness Loss at the Date of Next Inspection: Shell
C.4.k Estimated Thickness Loss at the Date of Next Inspection: Tubing
C.4.l Estimated Thickness Loss at the Date of Next Inspection: Head
C.4.m MAWPCURRENT: Process Side
C.4.n MAWPNEXT
C.4.o Is MAWPNEXT < MROP or PSV Set Pressure (Y/N)
C.4.p Recommended Internal Re-inspection Date
C.4.q Remaining Life (Years)
Page 20 of 25
Appendix D – Heat Exchanger Inspection Results Information
D.1 General Inspection Data

D.1.a Inspection Date
D.1.b Inspection Type (On or Off-Stream)
D.1.c NDT Methods Used (Text)
D.1.d Nameplate Details Checked (Y/N)
D.1.e Minimum Head Thickness (in)
D.1.f Minimum Shell Thickness (in)
D.1.g Inspection Findings (Text)
D.1.h Tubes Plugged (No.)
D.2 External Inspection Data

D.2.a External Paint or Insulation Condition
D.2.b Earthing Connection Condition
D.2.c Condition of Nozzles (Text)
D.2.d Condition of Supports (Text)
D.2.e Condition of Associated Piping (Text)
D.3 Internal Inspection Data

D.3.a Condition of Internal Components (Text)
D.3.b Service Related Cracking Detected (Y/N)
D.3.c CP Anode Condition (Text)
D.3.d Internal Lining (Coating) Condition (Text)
D.3.e Maximum Shell Pit Depth (in)
D.3.f Maximum Front Head Pit Depth (in)
D.3.g Maximum Rear Head Pit Depth (in)
D.3.h Maximum Channel Pit Depth (in)
D.3.i Maximum Tube Internal Pit Depth (in)
D.3.j Maximum Tube External Pit Depth (in)
D.3.k Description of Pit Sizes and Locations (Text)
D.4 Recommended Follow-up Actions

D.4.a C&I Recommended New Grade
D.4.b C&I Recommended Next External Inspection Frequency
D.4.c C&I Recommended Next Internal Inspection Frequency
D.4.d Internal Lining (Coating) Requires Repair (Y/N)
D.4.e External Paint Requires Repainting (Y/N)
D.4.f Recommended Weld or Other Repairs (Text)
D.4.g Summary of Follow-up Actions/Repairs Performed and Dates (Text)
D.4.h Recommended Tubes to Plug
D.5 Calculated Results Based on Inspection Information

D.5.a Minimum Allowable Wall Thickness (MAWT) of Shell
D.5.b Minimum Allowable Wall Thickness (MAWT) of Head
D.5.c Shell Short Term General Corrosion Rate
D.5.d Channel Short Term General Corrosion Rate
D.5.e Tubing Short Term General Corrosion Rate
D.5.f Front Head Short Term General Corrosion Rate
D.5.g Rear Head Short Term General Corrosion Rate
D.5.h Shell Long Term General Corrosion Rate
Page 21 of 25
D.5.i Channel Long Term General Corrosion Rate

D.5.j Tubing Long Term General Corrosion Rate
D.5.k Front Head Long Term General Corrosion Rate
D.5.l Rear Head Long Term General Corrosion Rate
D.5.m Shell Short Term Pitting Corrosion Rate
D.5.n Channel Short Term Pitting Corrosion Rate
D.5.o Tubing Short Term Pitting Corrosion Rate
D.5.p Front Head Short Term Pitting Corrosion Rate
D.5.q Rear Head Short Term Pitting Corrosion Rate
D.5.r Shell Long Term Pitting Corrosion Rate
D.5.s Channel Long Term Pitting Corrosion Rate
D.5.t Tubing Long Term Pitting Corrosion Rate
D.5.u Front Head Long Term Pitting Corrosion Rate
D.5.v Rear Head Long Term Pitting Corrosion Rate
D.5.w Worst Case Corrosion Rate
D.6 Calculated Results Based on Inspection Information

D.6.a Estimated Thickness Loss at the Date of Next Inspection: Shell
D.6.b Estimated Thickness Loss at the Date of Next Inspection: Channel
D.6.c Estimated Thickness Loss at the Date of Next Inspection: Tubing
D.6.d Estimated Thickness Loss at the Date of Next Inspection: Front Head
D.6.e Estimated Thickness Loss at the Date of Next Inspection: Rear Head
D.6.f MAWPCURRENT: Process Side
D.6.g MAWPCURRENT: Transfer Side
D.6.h MAWPNext
D.6.i Is MAWPNext < MROP or PSV Set Pressure (Y/N)
D.6.j Recommended Internal Re-inspection Date
D.6.k Remaining Life (Years)
In addition to the previous table, the following are required for the tubes of heat exchangers:
Defects Documentation for Heat Exchangers (Internal / External)
Erosion near tube end 1. Tube location / position

2. Updated exchanger drawing
Leaking tube 1. Tube location / position

Other tube damage 1. Tube location / position

3. Details of problem
Page 22 of 25
Appendix E – Pressure Vessel Inspection Results Information

E.1 General Inspection Data
E.1.a Inspection Date
E.1.b Inspection Type (On or Off-Stream)
E.1.c NDT Methods Used (Text)
E.1.d Nameplate Details Checked (Y/N)
E.1.e Minimum Head Thickness (in)
E.1.f Minimum Shell Thickness (in)
E.1.g Inspection Findings (Text)
E.2 External Inspection Data
E.2.a External Paint or Insulation Condition
E.2.b Earthing Connection Condition
E.2.c Condition of Nozzles (Text)
E.2.d Condition of Supports (Text)
E.2.e Condition of Associated Piping (Text)
E.3 Internal Inspection Data
E.3.a Condition of Internal Components (Text)
E.3.b Service Related Cracking Detected (Y/N)
E.3.c CP Anode Condition (Text)
E.3.d Internal Lining (Coating) Condition (Text)
E.3.e Maximum Shell Pit Depth (in)
E.3.f Maximum Head Pit Depth (in)
E.3.g Description of Pit Sizes and Locations (Text)
E.4 Recommended Follow-up Actions
E.4.a Recommended New Grade
E.4.b Recommended Next External Inspection Frequency
E.4.c Recommended Next Internal Inspection Frequency
E.4.d Internal Lining (Coating) Requires Repair (Y/N)
E.4.e External Paint Requires Repainting (Y/N)
E.4.f Recommended Weld or Other Repairs (Text)
E.4.g Summary of Follow-up Actions Performed and Dates (Text)
E.5 Calculated Results Based on Inspection Information
E.5.a Minimum Allowable Wall Thickness (MAWT) of Shell
E.5.b Minimum Allowable Wall Thickness (MAWT) of Head
E.5.c Shell Short Term General Corrosion Rate
E.5.d Head Short Term General Corrosion Rate
E.5.e Shell Long Term General Corrosion Rate
E.5.f Head Long Term General Corrosion Rate
E.5.g Shell Short Term Pitting Corrosion Rate
E.5.h Head Short Term Pitting Corrosion Rate
E.5.i Shell Long Term Pitting Corrosion Rate
E.5.j Head Long Term Pitting Corrosion Rate
E.5.k Worst Case Corrosion Rate
E.5.l Estimated Thickness Loss at the Date of Next Inspection
E.5.m MAWPCURRENT
E.5.n MAWPNEXT
E.5.o Is MAWPNEXT < MROP or PSV Set Pressure (Y/N)
E.5.p Recommended Internal Re-inspection Date
E.5.q Remaining Life (Years)
Page 23 of 25
Appendix F – Critical Input Data
F.1 Inspection type (planned, unplanned, routine, pre-shutdown, or shutdown)

F.2 Paint condition (including textual description)
F.3 External corrosion (including textual description)
F.4 Inspection type (visual/NDT/both)
F.5 Date inspected
F.6 Leak history data and date
F.7 Hydrotest conditions and date
F.8 List of inspection method, findings, recommendations and comments on findings, as applicable:
Page 24 of 25
Appendix G – Tank Data Recording Requirements
G.1 In-Service Inspections

G.1.a Foundation inspection (text)
G.1.b Annular plate (outside shell) (text)
G.1.c Tank shell (text)
G.1.d Roof structures and accessories (text)
G.1.e Roof seals (text)
G.1.f Fixed roof supports (text)
G.2 Out of Service Inspections

G.2.a Shell-Min. thickness by plate # (int/ext)+ inspection type
G.2.b Floor-Min. thickness by plate # (int./ext/) + insp. type
G.2.c Roof-Min. thickness by plate # (int./ext) + insp. type
G.2.d Repair summary by floor plate or other equipment
G.2.e Re-inspection timing for routine, pre-shutdown and shutdown inspections
G.2.f Dimensional Survey (Text)
G.2.g Memo/text
G.2.h Remarks
G.2.i Repairs/date (text)
G.2.j Outstanding activities (text)
G.2.k Recommendations
G.2. l Bottom coating condition and repairs details
G.2.m vacuum testing of weld seams for bottoms repairs
G.3 Calculations
G.3.a Minimum height for required hydrotest (API 653)
G.3.b Calculate and highlight where plate thickness is G5% of nominal thickness
G.3.c Minimum shell plate thickness based on height (API 653)
G.3.d Date of next inspection (calculated)
G.3.e Internal pressure at max. service height
G.3.f Minimum floor plate thickness
G.3.g Minimum thickness for annular plate ring
G.3.h Minimum thickness for the shell based on height
G.3.i Minimum Remaining Thickness (MRT) at the end of the in-service period of operation until the next
T&I as per SAES-D-108 or API 653.
G.4 Typical Output/Report Information

G.4.a Same as critical input data with calculation information
G.4.b Generate inspection schedules
G.4.c Generate workpacks (with appropriate inspection drawings)
G.4.d Graphical outputs of results
G.4.e 1. Tank calibration procedure shall be in accordance with SAEP-22.
2. Completed calibration report and the capacity tables generated shall be submitted.
Page 25 of 25

Saep 1624

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Saep 1624

Enviado por

Direitos autorais:

Formatos disponíveis

Engineering Procedure

SAEP-1161 26 March 2015

Saudi Aramco DeskTop Standards

Appendix A - Sample Report Form Layout and References................. 16

Previous Issue: 15 March 2010 Next Planned Update: 26 March 2020

Primary contacts: (1) Kakpovbia, Anthony Eyankwiere (kakpovte) on +966-13-8801772

Copyright©Saudi Aramco 2015. All rights reserved.

This Saudi Aramco Engineering Procedure provides,

3 Conflicts and Deviations

3.2 Deviations and Waivers

Direct all requests to deviate or waive the requirements of this Procedure in

 Saudi Aramco References

Saudi Aramco Engineering Procedures

Saudi Aramco Engineering Standards

Saudi Aramco Inspection Procedures

Saudi Aramco General Instructions

Saudi Aramco Forms, Data Sheets and Miscellaneous

5 Definitions and Abbreviations

Defect Notification: Defect notification is a document issued to operations for

Defect Notification Tracking System: System developed by the Saudi Aramco

Equipment Inspection Schedule (EIS): An approved record governed by SAEP-20

I5 Notification: T&I Notification generated automatically by the SAIF system before

Inspector: An inspector / inspection engineer is an employee who is qualified to

MAWP: Maximum Allowable Working Pressure

OIU: Operations Inspection Unit. Same as Plant Inspection Unit.

SAIF: SAP Application for the inspection of facilities

Shutdown Memorandum: A package containing the shutdown related documents

T&I Acceptance Report: T&I Acceptance Report (Form SA-3060-ENG) is a

6.1 Pre-T&I Report

h) Cathodic Protection (CP) inspection reports recommendation.

cleaning, and during the planned repairs work.

6.2 Post T&I Report

c) Reason for inspection and date inspected

6.2.2 Report Layout shall have continued pages and contain:

6.2.3 The inspection reports shall be drafted by the assigned inspector;

d) Date of the next internal inspection, together with any special

6.2.5 Facilities with storage tanks used for Royalty/Custody measurement

6.3 T&I Summary Report

6.3.1 Shall include an executive summary, brief highlight of the

6.4 Maintaining Inspection Reports

6.4.1 Record of the inspection activities for each equipment shall be

6.4.2 Maintain marked drawings (P & IDs, isometrics, schematics, etc.)

6.4.3 Relevant updated isometrics showing inspection locations shall be

6.4.4 Technical correspondence relevant to equipment inspected shall be

6.4.5 SISs of the equipment shall be updated if necessary and maintained.

6.4.6 Boilers chemical cleaning records shall be maintained in a format which

6.4.8 Appendices C to F contain Tables which documents the data required to

6.5 SAIF Utilization

7.1 Supervisor, Operation Inspection Unit shall:

7.1.4 Alert proponent management of any significant events or any changes

7.1.6 Assign a reviewer to validate quality of T&I data uploaded in SAIF.

7.1.7 Approve the Pre-T&I and Post-T&I reports in SAIF.

7.2 Field Supervisor, Operation Inspection Unit, shall:

7.2.1 Review the equipment inspection final report, T&I recommendations,

7.2.2 Complete approvals in SAIF as required.

7.3 Inspector, Operation Inspection Unit, shall:

7.3.1 Maintain records of each inspection activity for each equipment, in a

7.3.2 Document all reports and tests/examinations results including pressure

piece of equipment and upload in SAIF.

7.3.4 Document corrective actions taken to address non-conforming items

7.4 NDT Coordinator, shall:

7.5 Supervisor, Engineering Unit responsible for design packages in proponent

7.5.1 Provide revamps/project proposals and recommendations for the