PARTICIPANT

PEW 107.02

SAUDI ARAMCO

INSPECT EXISTING PIPELINE PIPING

WARNING: The training materials contained in this manual are the property of the Saudi Arabian Oil Company (Saudi Aramco) and are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses. Any material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramco's Professional Engineering and Technical Development courses without the prior written permission of the Chief Engineer of Saudi Aramco.

PEW 107.02 PARTICIPANT

REVISION

DATE REVISION DESCRIPTION

PAGE(S) AFFECTED

PEW 107.02

PARTICIPANT

TABLE OF CONTENTS

MODULE COMPONENT

PAGE

OBJECTIVES INFORMATION

Introduction 2

1

Prepare for Inspection of Existing Pipeline

Piping 3

Inspect Buried Pipeline, Transition Points and

Pipe Supports 8

Inspect Pipeline Coatings 14

Inspect Piping 18

Document Inspection Results 23

EXERCISES

Exercise 1.

Exercise 2.

Exercise 3. Exercise 4. Exercise 5.

Prepare for Inspection of Existing

Pipeline Piping 28

Inspect Buried Pipeline,

Transition Points and Pipe

Supports 30

Inspect Pipeline Coatings 32

Inspect Piping 34

Document Inspection Results 36

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TABLE OF CONTENTS

WORK AIDS
Work Aid 1. How to Prepare for Inspection of
Existing Pipeline Piping 38
Work Aid 2. How to Inspect Buried Pipeline,
Transition Points and Pipe
Supports 39
Work Aid 3. How to Inspect Pipeline
Coatings 41
Work Aid 4. How to Inspect Piping 43
Work Aid 5. How to Document Inspection
Results 44
GLOSSARY 49
EVALUATION 50
ADDENDUM 56 iii

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OBJECTIVES

OBJECflVES

Terminal Objective

Upon completion of this module, the participant will be able to inspect existing pipeline piping according to applicable standards.

Enabling Objectives

In order to accomplish the terminal objective, the participant will:

o Prepare for inspection of existing pipeline piping.

o Inspect buried pipeline, transition points and pipe supports.

o Inspect pipeline coatings.

o Inspect piping.

o Document inspection results.

Note: This training material has been developed using the latest available versions of applicable Saudi Aramco and industry standards. However, these documents are regularly updated; therefore, it is the responsibility of the inspector to ensure that he is conducting his inspections according to the latest versions of these documents.

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INFORMATION

INTRODUCTION

Purpose

Pipelines are the essential link between oil and gas reservoirs and their users around the world. Maintaining these pipelines is vital in sustaining the flow of these fluids between well head, pumping stations, storage tanks, and shipping points.

Inspection of existing piping and installations is essential in:

o Maintaining pipeline safety

o Achieving maximum reliability

o Achieving maximum servlceabillty

Scope

This module consists of guidelines for inspecting existing pipeline piping, such as flowlines, trunklines, mainlines, their associated tie-ins and appurtenances. These include aboveground and buried piping, valves, pipe supports and external coating systems.

This module covers information previously covered in many separate modules. The inspection of pipelines is a project Projects require combining the knowledge of many different inspection procedures. This module does not cover the information of prior training. You should review previous training modules and applicable inspection standards, which will provide additional information or clarify questions on pipeline piping inspection.

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INFORMATION

PREPARE FOR INSPEO"ION OF EXISTING PIPELINE PIPING

Before beginning your inspection of existing pipelines, you must ensure that you are adequately prepared. To assure a safe and thorough inspection of the pipeline, you must first familiarize yourself with all applicable pipeline reference documents. These documents provide you the following information:

o Pipe diameter

o Pipe wall thickness

o Pipe material type, grade and method of fabrication

o Pipeline product

o Location safety design factors

o Design and operation pressures

o Applicable design code

o Last hydrostatic testing and test pressure

o Operational state (in-service/ shutdown/ mothballed/ abandoned)

o Route/ location

o Type of coating system used

o Cathodic protection (CP), if any

o Age of pipeline

o Date of last T&I

o Past leakrepair reports

o Current inspection reports

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INFORMATION

Pipeline Data Books

The first item that should be reviewed is the Pipeline Data Book. Pipeline data books provide you with information about the jurisdiction, location, design specification, operational characteristics and safety instructions on the pipeline. Pipeline data books contain the following information:

c Pipeline Route Maps

o Piping and Instrumentation Diagrams (P&IDs)

o Safety Instruction Sheets (SIS)

o Corrosion Chart Sheets

o Minimum Design Wall Thickness Sheets

o Scraper Trap Drawings

o OSPAS Valve Lists

Pipeline Route Maps

Pipeline route maps show the plan views of all pipelines relative to each other and any existing plants and roadways. These maps are very helpful for initially locating the route of each pipeline. Pipeline markers can further help pinpoint the exact locations of aboveground and buried pipelines.

Piping and Instrumentation Diagram

P&IDs are schematics of pipeline piping systems. They define the process, material specifications, sizes and the orientation of the piping, valves, instrumentation and flange connections in the pipeline.

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INFORMATION

Safety Instruction Sheet (SAF 5645-1)

The Safety Instruction Sheet (SIS) provides information on the pipeline. It is the most important piece of information about the pipeline. Some of the information found in the SIS includes:

o Pipe size

o Nominal wall thickness

o Type of pipe material and grade

o Pipe manufacture type

o Calculated design pressure

o Maximum allowable operating pressure (MAOP)

o Type of product transported through the pipe

o Governing design code

o Calculated minimum design wall thickness

o Starting and ending points of each pipeline segment

o Specifies if the segment is above or below ground

o Hydrostatic tests performed, test pressures, date of last test

o Other pertinent safety-related data

Corrosion Chart Sheets

Corrosion chart sheets provide you with the acceptable limits of corrosion metal loss on pipeline piping. These sheets define the maximum acceptable depth and length of any isolated corrosion pit or corrosion lake along the length of the pipeline piping. The data points in these graphs have been calculated from formulas defined in ASME 831 G, "Manual for Determining the Remaining Strength of Corroded Pipelines." Use this information to identify acceptable corrosion metal loss.

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INFORMATION

Minimum Design Wall Thickness Sheets

Minimum design wall thickness sheets list the calculated design wall thickness of all segments of the pipeline. The minimum design wall thickness (t) is calculated using Barlow's Formula, which is:

t- PD - 2SF

Where: P = Maximum allowable operating pressure (psig) D = Nominal pipe size (in.)

S = Specified yield stress of the pipe material (psi) F = Safety design factors (according to SAES-L-003)

Scraper Trap Drawings

Scraper trap drawings, located in the Pipeline Data Book, are an indication that the pipeline is equipped with scraper facilities. These drawings define the starting and ending location points of the scraper facility and its fabrication specifications. Use this information when planning the pipeline scraper inspection.

OSPAS Valve list

The OSPAS valve list identifies all isolation valves within the pipeline. Each valve is assigned an OSPAS number and area/kilometer marker for identification. The OSPAS valve list provides technical and operational data, such as make of valve, valve type, size, type of end connection, flange type and primary pressure rating, actuator specifications, and type of product flow.

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INFORMATION

Inspection Worksheets (SAF 2643) and Leakage/Repair Reports (SAF 7212)

All previous inspections of the pipeline are recorded on Inspection Worksheets. Any leaks and/or repairs are recorded on the Pipeline Leakage/Repair Report. Worksheets provide a history of the types of inspections performed on the pipeline. Leakage/repair reports show past pipeline damage and provide a basis for the types of damage to expect and their probable locations. Review these documents and make notes on possible problem areas. These documents will indicate the number of inspections made on the pipeline, the date and frequency of each inspection, any damage findings and the course of action taken. These reports can provide you with an understanding of the overall condition of the pipeline.

Applicable Codes and Standards

Addendum A is a list of recommended practices and standards for inspecting existing pipelines. Use this list for reference material on inspection of existing pipelines. Documents should be available at the work location. Obtain documents not available at the work location from the Technical Information Center in the Engineering Building, Dhahran.

Inspection Equipment

Before performing an inspection, assemble and check your inspection tools and equipment, including:

o Portable lights, including flashlight

o Magnifying glass

0 Rulers and tapes
0 Pit depth gauge
0 Straight edges
0 Paint or crayon
0 Thin-bladed knife
0 Scraper
0 Wire brush
0 Notebook or sketches You may need other specialized equipment, depending on the type of inspection you will perform.

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INFORMATION

INSPECT BURIED PIPELINE, TRANSITION POINTS AND PIPE SUPPORTS

Pipelines are buried beneath the ground surface, or laid on the surface and covered with soil (berms), or laid on supports a short distance above the surface (Figure 1). Pipelines are buried below-ground to protect them from vehicle damage, to reduce congestion, or because of safety regulations that protect the surrounding population and environment Aboveground pipelines are normally laid on pipe supports to keep them from touching either the ground surface, other pipelines or a body of water.

Traffic barrier r Edge of road I _pavemen,

r---------f..___l___:_:::::;

1---- Edge of road berm

\_ Pipe wall thickness per AES-L-046

1.00m

Figure 1. Above-and below-surface pipeline

Proper ground cover over the pipeline (backfill) provides protection against vehicle traffic and keeps it from pulling out of the ground due to high temperatures and internal pressure. Damage due to vehicle traffic or excavation near the buried pipeline is the greatest cause of pipeline failure. High temperature and pressure can cause sections of buried pipeline to rise out of the ground. This action is called pipeline loop-out and can be prevented by proper ground cover. SAES-L-OS1, Construction Requirements for Cross-country Pipeline, specifies the minimum requirements for ground cover. Generally, LPG lines, gas lines and oil well flowlines must have a minimum ground cover of 3 feet (900 mm).

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INFORMATION

Surface pipelines require support to elevate them above the ground. Above-ground pipelines must not hinder the movement of sand and water around them. This damming effect would cause stress to the coatings and to the pipe that would lead to early failure. Aboveground pipelines must have adequate support for the pipe and the liqUid it carries. There must be means for the pipe to expand and contract during periods of heating and cooling.

Buried Pipeline

Pipeline mayor may not have external corrosion barriers, such as tape wrap or epoxy coatings. In any case, you must have access to the pipe surface to perform any type of inspection except instrument scraping. This requires excavation and some surface preparation. The pipe surface must be free of adhering substances, such as failed or damaged coatings, rust, scale, or dirt, which might conceal a damaged area.

Excavation for Inspection

Sections of pipeline are initially excavated in several locations along the length of the pipeline to provide an overall assessment of its condition (bell-hole inspection). Excavate and inspect at locations that are susceptible to corrosion damage. These locations include low points along the elevation profile of the pipeline and at the soil-to-air (S/A) transition points. Excavation on in-service, pressurized pipelines can be a hazardous operation if proper safety procedures are not followed. Ensure that excavations deeper than four feet are either shored up or have the side sloped with an angle not exceeding 34 degrees (a ratio of 1 to 1.5 slope) to prevent cave-in. GI 434.000, Pipeline Repair and Maintenance, covers this in detail. The excavation should be enough to provide you with a minimum sixteen inches of clearance around the circumference of the pipe.

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INFORMATION

Soil-to-Air (SI A) Transition Points

Soil-to-air transition points are locations where aboveground piping goes below ground level to become buried piping, or buried piping emerges to become aboveground piping. These points are critical because they are most susceptible to coating failure and corrosion damage due to soil stresses and moisture accumulation. Conduct periodic inspections of a pipeline's S/A transition point Check for damaged or failed coating systems and subsequent corrosion damage. If you see damaged coating and corrosion, continue removing damaged coating until you find sound coating and base metal. Identify damaged locations in the inspection report to ensure that proper coating repair is made.

Inspect S/A transition points that have concrete interfaces for evidence of cracked or friable concrete. Chip it away until you reach sound concrete and the pipe surface shows no corrosion damage. After the inspection and any repairs are completed, ensure that the concrete is repaired to prevent further corrosion damage.

Pipe Supports

Aboveground pipelines must be properly supported to prevent excessive sagging. This causes bending stresses in the pipe. Typical aboveground supports consist of ring girders, concrete supports or H-beams. Visually inspect the condition of the supports and piping support interface. Report ring girders or H-beam supports that are bent or broken. Report concrete supports that are crumbling and fraying apart from the reinforcing bars. Verify support spacing. Incorrect support spacing causes high bending stresses at the piping support interface and will cause corrosion or cracking. Piping and pipe supports located near marine facilities use coatings and cathodiC protection (CP) to protect them from corrosion. Report any coating or cathodic protection damage on the supports. Specifications for support types and spacing are provided in SAES-L-051 and Standard Drawing AB-36530.

Inspect the various types of support for any problems that may affect the safety of the pipeline. Three designs of pipe supports are in use:

o Portable pipe support

o Anchor-type pipe support

o Raised pipe support

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INFORMATION

Portable Pipe Support

The portable pipe support (Figure 2) is the most common type of pipe support used by Saudi Aramco.

Inspect these supports for cracking and spalling of the concrete. Verify the correct spacing of the supports. Verify that the spacing matches the plot plan.

LO LO C')

Grade in

o o

~

<i I

o LO

~

o C') C\I

Figure 2. Portable concrete pipe support

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Anchor-type Pipe Support

The anchor-type pipe supports (Figure 3) are used at points where the pipeline attaches to equipment, branch lines or trunk lines.

This pipe support allows the pipe to pass through a pipe sleeve. The welds that join both halves of the sleeve are not welded to the pipe. The sleeve contains a backing that prevents the weld from adhering to the pipe. The sleeve also contains a vent or weep hole that permits moisture to escape.

Inspect these types of supports for cracking or spalling of the concrete. Check for signs of movement,. where the pipe attaches to the support. Verify that the weep hole is clear of obstruction. Verify the alignment and spacing of the support with the plot plan.

600

~---- Pipe sleeve

o <D C')

25mm Grout

C\I m C')

,

125 I

350

,

I 125

Figure 3. Anchor-type pipe support

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INFORMATION

Raised Pipe Support

The raised pipe support (Figure 4) holds the pipeline further above the ground. This type of support will be found where the pipeline must be maintained at a standard elevation while crossing washouts (wadi) or other obstacles.

Inspect these supports for cracking or spalling of the concrete. Inspect the metal of the support for any signs of corrosion. Inspect the bolts that attach the metal to the concrete, looking for loose or broken bolts. Verify the spacing of the supports with the plot plan.

~
i
I
,
,
I
,
I
... , ! ...
III III
" Fin. grade Ii Ii
t t




. .

. .
Figure 4. Raised pipe support

Refer to PEW 402.01 (Inspect Backfill) and PEW 402.02 (Inspect a Pipeline Rightof-Way) for more information.

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INFORMATION

INSPECT PIPELINE COATINGS

Because of the generally dry, hot climate conditions in Saudi Arabia, most aboveground pipelines do not have external coatings unless they are located near a marine environment. SAES-H-002, Internal and External Coatings for Steel Pipelines and Piping, lists other situations that require aboveground pipelines to be coated. The primary means of protecting piping from corrosion were applied when the pipeline was initially laid. Inspect the coating to detect any conditions that might lead to the failure of the coating or pipe. Before the inspection, consult the Pipeline Data Book to determine which type of coating or coatings have been used. This pipe protection usually consists of one of three types of protective coatings:

o Tape wrapping

o Heat shrink sleeves

o External fusion-bonded epoxy (FBE) coating

Inspect Tape Wrapping

For many years, tape wrap was the primary type of coating system used on buried pipelines. Tape wrap is applied spirally around the pipe in continuous sheets of polyethylene wrap. Tape wrapping is usually applied in two layers. The edges of the first layer overlap the second layer to ensure total surface coverage. Both layers of tape wrap have self-adhesive backing for bonding to the pipe surface. Primarily due to improper surface preparation, tape wrap has not been very reliable in preventing corrosion. Disbonding has been the primary problem with tape wrap. Moisture gets between the tape wrap and the pipe surface, causing corrosion damage. There is also a correlation between stress corrosion cracking, a form of base metal cracking, and tape wrap disbondment and cathodic protection. Corrosion damage can go undetected under tape wrap. The exterior surface may appear undamaged, but underneath, the corrosion process is active. Saudi Aramco has phased out all use of tape wrapping, except for minor coating repairs, in favor of epoxy coating systems.

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INFORMATION

Damages to tape wrap coatings consist of disbondment or mechanical damage such as cuts, spalling and abrasion. Look for signs of tape wrap disbondment, such as bulging and wrinkles on the tape surface. Thermal expansion and contraction of a pipeline can pull tape wrap off the pipe surface. Over a period of years, tape wrap may show signs of wrinkling or sliding up the axis of the pipe.

Look for any inconsistencies in the tape. Any surface deterioration may indicate that the tape is allowing moisture to contact the piping. Inspect for any leaks of fluid through the tape that would indicate a major failure of the coating.

If no telltale signs of damage can be seen, you may still want to inspect for any unnoticeable disbondment This can be done by conducting a window-type patch test To perform this test, use a sharp knife to cut a 1" square out of the tape wrap. Lift the tape up. The adhesion of the tape wrap is acceptable if the exposed pipe has a complete cover of adhesive or if strings of adhesive appear as the tape is peeled back, and no areas of zero adhesion are seen. Ensure the repair of the area patch test is done using a new tape wrap; follow the guidelines of AES-H-203, Hand-applied Tape Wrapping of Buried Pipe.

If the tape wrap fails the test or corrosion is present under the window, conduct other tests at different intervals along the pipe to determine the extent of the problem. Removal and re-application of the tape wrap are necessary when a large area of tape wrap has failed.

Inspect Heatshrink Sleeves

Heatshrink sleeves are used for coating repairs on fusion-bonded epoxy {FBE}-coated piping, small diameter pipe, and piping with irregular surface areas, such as girth welds and elbows. Heatshrink sleeves are superior to tape wrap when covering irregular surfaces. They also have higher operating temperature ranges than most tape wrap.

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INFORMATION

Heatshrink sleeves are applied around the circumference of a pipe in premeasured sheets which overlap at the ends. Before installing heatshrink sleeves, the surface of the pipe is preheated to a prescribed temperature that makes the sleeve adhere to its surface. Once the sleeve is wrapped around the pipe, a closure patch is applied across the ends and heated to seal them. Once in position, the entire sleeve is heated further to shrink it tightly against the pipe surface. The sleeve is massaged to ensure complete contact with the pipe surface and to remove any remaining voids or air pockets. Heatshrink sleeve material is not compatible with any type of hydrocarbon environment. This means that all backfill surrounding the heatshrink sleeve coating must not contain any form of hydrocarbon; otherwise, the sleeve will break down rapidly.

Inspect heatshrink sleeves visually. Ensure that the sleeve is smooth. Perform a window-type patch test on areas of the heatshrink sleeve suspected of damage. All damaged areas shall be cut out and repaired according to SAES-H- 204V, Approved Vendor Installation Procedures for Heatshrink Sleeves.

Inspect External Fusion-bonded Epoxy Coating

FBE coating is applied in the field or shop to the pipeline before installation. It is a shop-applied phenolic epoxy coating system that requires special base metal preparation to ensure proper anchorage of the coating. The coating requires induction heaters to pre-heat the pipe before coating and special applicators to spray the powder-base epoxy on the pipe. The powder-base epoxy reacts chemically when sprayed on the heated pipe surface to form a very strong surface.

Other epoxy coating systems have been developed for field application. These coating systems do not require heat to cure the epoxy. They rely on a chemical reaction between an activator and the epoxy, which are mixed together before application. These systems are primarily used for pipeline renovation and coating repairs. Although these systems do not require preheating, as the FBE system, they still require the same surface preparation. Epoxy coating systems can be satisfactorily applied over most irregular surfaces. They have superior corrosion-resistance properties and can withstand higher operating temperatures. They will not break down when exposed to hydrocarbons or ultraviolet light, and have a high resistance to mechanical damage and soil stresses.

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Typical damage to epoxy coatings consists of disbondment, blistering, flaking, and mechanical damage, such as cuts, spalling and abrasion.

Always consult AES-H-002 and AES-H-200 for specific guidance before repairing FBE coatings. For additional information, review PEW 105.06, Maintenance Inspection/Existing Coatings, and the PEW 409 Series, Coatings.

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INSPECf PIPING

The visual inspection is the most-used method of pipeline inspection. Even if the line has been previously inspected by remote methods, such as instrument scraping, a visual inspection is needed to provide confirmation and other additional information before work can begin.

Piping Inspection

Leakage is the obvious result of pipeline defect. Leakage on aboveground pipelines can easily be detected during routine pipeline patrolling, unlike buried pipelines, whose leakage can only be detected after the surrounding area is either saturated with the product or by its noxious, permeating odor. In either buried pipeline or aboveground pipeline, non-leaking, less obvious forms of damage, such as corrosion pitting, dents, gouges and cracks, usually go unnoticed. These forms of damage will remain undetected until an inspection is done or until they form a leak or rupture.

Pressurizing a pipeline above its maximum allowable operating pressure will sometimes force damaged areas to leak if they are severe enough. This type of inspection is called a revalidation hydrotest. Unfortunately, this inspection method does not provide a quantitative analysis of the pipe damage. A pipeline can pass a revalidating pressure test only to leak at some later date. Water is usually used as the pressure testing medium, although the pipeline'S product can sometimes be used under certain circumstances and conditions.

Visible surface defects can be detected by either a visual inspection, usually recorded on documents as vr (visual testing), or a liquld penetrant inspection (PD. Surface damage that is too small to be noticed by the naked eye or which lies just below the pipe surface can be detected by a magnetic particle inspection (MT). Defects deep within the base metal of the pipe or those located on its inside surface can be detected by ultrasonic inspection (UT) or radiographic inspection (RT).

Another method of pipeline inspection is the intelligent scraper (PIG). PIGs are used for detecting both internal and external damages along the entire length of a pipeline, without excavating the line or requiring your presence during the inspection.

Each of these inspection methods requires its own specialized equipment, level of inspector qualification, and preparation in order to perform the inspection.

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Intelligent Scraper

The intelligent scrapers are specially designed instruments used to inspect the condition of lengths or sections of pipelines. They perform this inspection as they are propelled or pushed through the pipeline. They can inspect the condition of pipeline piping that is above ground, buried, coated, or bare, without requiring any excavation or the removal of protective coatings. Although these machines are primarily used to provide corrosion metal loss profiles, they can also detect mechanical damage, such as dents, gouges, bends and whether the pipe has gone out of round. The PIG is also capable of locating pipe girth welds, valve placements, fittings and the horizontal and vertical profile of the pipeline. PIGs employ either ultrasonic or magnetic flux leakage (MFL) sensors to perform these inspections. The sensors detect signals from any anomaly outside of a uniform run of straight pipe, which are then recorded on magnetic tape or computer disk and later analyzed.

Corrosion and Mechanical Damage

It is your job to detect, identify and report corrosion and mechanical damage in a concise and accurate fashion. The following steps may be used as a guide.

Step 1. Take an overall view of the pipe surface and outline each damaged

area with a crayon for later identification. Clusters of surface damage, such as corrosion lakes, can be regarded as a single defect area.

Step 2. Visually inspect, identify and label each defect area. Look closely for surface cracks, especially in areas that have been damaged by dents or gouges. If there is not enough lighting to perform the visual inspection, hold a flashlight at an angle to the surface to highlight any defects. Use a magnifying glass, if necessary.

You can use nondestructive examination (NDE), such as penetrant testing or magnetic particle testing, if you suspect surface cracking. Bulging of the pipe surface can suggest hydrogen damage, such as blistering, declamation or hydrogen-induced cracking (HIC). Radiography or ultrasonic testing should be used to properly identify these types of damage.

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Step 3. Measure the length, width and maximum depth of each defect area. If blisters are found, measure their height also. If individual defect areas are too close together, they can interact with one another and amplify the total damage to the pipe. Therefore, the distances between defect areas should also be considered when taking measurements.

The depths of dents, gouges, corrosion pits and lakes can usually be measured with a pit gauge. If the pipe surface is too badly corroded to allow level placement of the pit gauge, lay a straight edge across any uncorroded surface surrounding the damage. Measure the depth of the damaged area from the level edge of the straight edge. The use of UT inspection (D-meter) is much more accurate for measuring the remaining wall thickness of corroded pipe. It should therefore be a part of every inspection when external corrosion damage is detected.

Valves

There are four main categories of valves used in Saudi Aramco plants and piping service:

o Block valves

o Throttle valves

o Automatic control valves

o Check valves

Valves come in a wide range of sizes, from 114 inch to 42 inches and sometimes larger.

Valves are classified according to the pressure they can withstand. Valves come in class ratings of 150, 300, 400, 600, 800, 900, 1500, 2500, and 4500 pounds per square inch (psi).

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The main valve types based on the different body styles are:

0 Gate valve
0 Plug valve
0 Ball valve
0 Butterfly valve
0 Globe valve
0 Needle valve
0 Diaphragm valve
0 Angle valve
0 Automatic control valve
0 Check valve
0 Safety relief valve A visual inspection of a valve includes checking for leaks, such as around any flanged or screwed connections, packing glands or on the valve body. Many leaks around the flanged or threaded connections can be stopped simply by tightening the bolts or screwed connections. Likewise, leaks around the valve's packing can be stopped by injecting a sealant into the valve's sealant ports.

The valve's stem should be worked back and forth at least a half a turn to ensure it is not seized. The stem should also be protected with grease and covered to prevent seizure due to dry stem, corrosion or sand and grit.

Some valves are designed for only one-way directional flow. Although the orientation of these valves should have been checked during the initial installation, they may have been installed backwards. During the inspection, you should determine the flow and check for correct valve installation. Some valves display flow-indicating arrows. Figure 5 shows a typical valve.

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GLAND FOLLOWER

PACKING --------rllj GLAND BOLT

PACKING GLAND

PACKING

Figure 5. Cross section of a globe valve

Corrosion and mechanical damage on valves should be outlined, cleaned and inspected in the same manner as piping. Surface damage can usually be detected using visual, PT or MT inspection. Depending on the situation, UT or RT inspection (or both) may be used to detect and evaluate internal corrosion or mechanical damage. For example, a profile RT inspection can be used to detect internal mechanical damage, such as loose flappers inside check valves, a bent valve stem or a dropped valve gate inside a gate valve, or any foreign material inside any valve. UT inspection can detect internal corrosion and determine the remaining wall thickness. It can also be used to detect cracks which are unnoticeable by PT, MT or even RT inspection. Do not radiograph large valves in service, due to the long radiographic exposure required and the poor radiographic definition that results. You are required to evaluate the types of suspected damage and determine which type of NDE is most suttable

For additional information, review PEW 101, Saudi Aramco Valve Inspection, and PEW 102, UT by D-meter.

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DOCUMENT INSPECTION RESULTS

After you inspect pipeline piping, you must make concise inspection reports to record the inspection findings for further assessment and future records. Include all pertinent information in the reports, and send them to the appropriate departments for evaluation and/or follow-up inspections.

Write field notes to record data and information about inspections. These notes are personal observations about an inspection. Record all of your observations, findings, conclusions, and recommendations about the inspection. You will use these notes later when you write your reports.

Documents used to record the results include the:

o Projects Inspection Report (Saudi Aramco Form 8213)

o Inspection Worksheet (Saudi Aramco Form 2643)

o Pipeline Leakage/Repair Report (SAF 7212)

Projects Inspection Report (Saudi Aramco Form 8213)

Report the inspection on Saudi Aramco Form 8213, the Projects Inspection Report An example of this form appears in Figure 6. Form 8213 contains a record of the project and inspections performed. Write a brief statement in the remarks section about the inspection. Record the results of the inspection. Include any remarks about the kinds of repairs required to complete the inspection.

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PROJECTS INSPECTION REPORT

Saudi Aramco 8213 -ENGR (11/90)

SECTION: ....:..Ab=9,;;;:ai:,;;&9...:..P..:.,;ro""je.:;,;ct:;;,::;:...s __

ADDRESS: 6-32

o.

Abqaiq Pi

FAX:

To:

Maintenance Division

G-2323

Dhahran

epart No.

DPIU-PIR-1/1

Job Location

Abqaiq pipeline Km 24-Km 30

Date of Inspection

Jul 4,1992

Final inspection of the pipeline is complete and the following is noted:

1. Checked pipeline between Km 24 and Km 30.

2. This pipeline runs underground between Km 24 and Km 28.

3. Berms, markers, all valves checked out satisfactorily.

4. FBE coating on line between Km 28 and Km 30. Performed "X" test

every SOOm. No problems found.

5. Performed UT thickness measurements at previous test points.

Results contained on UT test report.

6. All supports checked and verified, no problems.

7. Condition of pipeline is satisfactory.

Inspector (Use any name) Date Tel. No. Signature
7/5/92 345-3456
SUpeMsor (Use any name) Date 7/6/92 Tel. No. Stgnature
231-4567 cc.

Figure 6. SAF 8213

24

PEW 107.02

PARTICIPANT

INFORMATION

Inspection Worksheet (Saudi Aramco Form 2643)

Use this worksheet to list deficiencies found during an inspection of equipment and to recommend repairs of that equipment. Fill this worksheet out and, if the discrepancies have not been corrected after 4 to 10 days, file a Non-conformance report (NCR). A completed Inspection Worksheet is shown in Figure 7.

This form is used to communicate between Inspection and Maintenance.

25

PEW 107.02

PARTICIPANT

INFORMATION

PAGE_OF_

WORKSHEET " BGP ENGINEERING INSPECTION I DATE PREPARED I WORKSHEET NO.
Saudi Ararrco 2643-ENG (11/90) INSPECTION REPORT 12/22/1992 578/92
EQUIPMENT (NAME) I EQUIPMENT NO. DATE INSPECTED
CENTRAL CONTROL ROOM
LOCATION WORK RECOMMENDED BY
476 CCR WEST EXIT. INSPECTION'S SIGNATURE
SERVICE I JOB ORDER :~
H.A. KAHAN
I SUPERVISOR'S SIGNATURE
FOR I 0 WORK ORDER (ARAMCO 981) ISSUED ON: (DATE) 12/22/1992 ~.
ACTION I A. ANTONIUO -
BY 0 OPERATOR'S SIGNATAURE
I W.O. NO. PRIORITY: C COMPL. DATE: 1/15/1993
H.A. AL ~
Operalor indicate action taken, sign and return one copy to Engineering Inspection. SULAIMAN
PRIORITY ITEM DESCRIPTION OF WORK TO BE DONE
FORMAT (SCOPE, FINDINGS, CONCLUSIONS, RECOMMENDATIONS)
SCOPE: Visual Inspection of leaks from C.C.R. roof, ( North Segment)

FINDINGS:
1 During the recent rains the C.C.A. roof developed leaks at the west interface of north and south segments of
C.C.A. building. The Interface comprises roof slab of north segment and west wall of the segment.
2 An Inspection through the ceiling tiles at the roof bottom revealed inadequately sealed construction joint
at the Interface.

CONCLUSION:
1 Leakage is due to poor joint design and construction.
2 It would be prudent to check the north interface of C.C.A. and n required carry out necessary repairs.

RECOMMENDATIONS:
1 Remove all the plies of roof fett along wHh the existing sealing material to
evaluate the extent of repairs required.
2 Re-seal the construction joint at the interface and rebuild the roof acceptable
to SAES-M-100

CONTACT:
DISTRIBUTION, cc: Figure 7. Completed Inspection Worksheet

26

PEW 107.02

INFORMATION

PARTICIPANT

Pipeline Leakage/Repair Report (SAF 7212)

Report any pipeline leaks and/or repairs on SAF 7212 (Figure 8). After final repairs are complete attach this form to the Projects Inspection Report. All of these reports will become a part of the pipeline data book at the completion of the project. Refer to PEW 108.03, Projects Reports and Records, for more information.

PIPELINE LEAK/REPAIR REPORT Aramco 7212 (SlBO)

DATE LEAK REPORTED DATE REPAIR STARTED DASTE REPAIR COMPLETED

-~~~/~~~~~~-- ~~:~~~~~T NO. ---;P""O""'IP=-: "7:134:7/""92=--

1011192 DATE 10103192

PIPELINE DATA

PIPELINE NAME FROM

TO

24" UTH GOSP-S TIL PLANT NO.

UTH GOSP-S SERVICE

UA-l PIL KM 66 MATERIAL

419

CRUDE OIL

X60

INSTALLATION YEAR -'-"9"-73"---- OUTER DIAMETER IN INCHES -"24"-." _

TOTAL LENGHT IN KMS ",4.,,-S WALL THICK NESS IN INCHES -"0.",25,,,,0,-" _

BURIED LENGTH IN KMS -,-,4.-,,-S --.-'C""O:::;.:,ATING TYPE PLiCOFLEX

ABOVE GROUND LENGTH IN KMS ° OJ RESTRAINED 0 NON-RESTRAINED

INSPECtffi~n1~EPORT

.u.w__'_"~ __ ---I.I~x~1 BURIED

RUPTURE POSITION _..S_,..O.,.IC'-- _

LENGTH OF LEAKIRUPTURE =4_" ----1_--,

LiJ CLEAN SAND W ROCKY I.....!...J MARL D SUBKHA EXISTING COATING APPEARANCE

D ABOVE GROUND

RUPTURE LOCATION

§ INTERNAL§ EXTERNAL

GENERAL PITS. MAX DEPTH

BANDS LAKES,MAX.DEPTH

SMOOTH ~ ADHERANT

CRACKED DETACHED

DAMAGED BRIDLE

6" CRACK

OTHER LEAKS/RUPTURE: (Explain)

CATHODIC PROTECTION RECTIFIES PROTECTING THE STRUCTURE

RATING

RATING

VOLTS AMPS

VOLTS AMPS

RECTIFIER UNITS NO:

PIPE TO SOIL POTENTIAL CURRENT ON:

VOLTS - CURRENT OFF:

VOLTS

REPAIR DETAILS

If $lee! plug was used, depth of penetration = NlA inches.

SIX (6) INCH CRACK OCCURED ON 24" UTH-GOSP-S TIL DURING HYDROTEST

BOTH CRACK TIPS WERE ELIMINATED BY TORCH, THEN PLiDCO SLEEVE WAS INSTALLED ON THE

CRACKED AREA AS PER GI441.012

REMARKS:

THE CRACKED JOINT NEED TO BE REPLACED AS RECOMMENDED

PER POIM: 625192

INSPECTOR: A.S. AL-BASHAKlI.K AL-KHAMEES

SUPERVISOR: A.M. AL-AUDAH /0/0//92

DISTRIBUTION:

Supt., SAPOD

Supt., C.P. Div. Coordinalor, MSD (T-Sl0)

Supt., Oper. Insp. Div. CSD

Inspector File

Plant File No. 419

Figure 8. Pipeline Leakage/Repair Report

27

PEW 107.02

PARTICIPANT

EXERCISE

EXERCISE 1.

PREPARE FOR INSPECTION OF EXISTING PIPELINE PIPING

Using the information provided in the work aids and Information section, answer the following questions.

Fill in the blank with the letter of the correct answer or answers.

1. Inspection worksheets provide you _

A Pipe material type, grade and method of fabrication

B. A history of previous inspections performed on the pipeline

C. Design and operation pressures

D. Age of pipeline

2. When preparing for the inspection of the pipeline which item will you

check first? _

A SIS

B. P&IDs

C. Previous UT thickness measurements

D. Pipeline data book for the pipeline

3. The Safety Instruction Sheet will provide information on _

A Coatings

B. Previous UT thickness measurements

C. Valves and junctions

D. Calculated minimum design wall thickness

28

PEW 107.02

PARTICIPANT

EXERCISE

4. When reviewing past Leakage/Repair Reports you should make a note of

what? _

A. Any problem areas that have been of concern to previous

inspectors

B. Condition of the coating

C. Location of the oldest component of the pipeline

D. Locations of pipelines

5. Corrosion chart sheets provide information on _

A. Operation of the D-meter

B. Protective coatings type and depth

C. Test point locations and remaining life of the pipe

D. Acceptable limits of corrosion metal loss

29

PEW 107.02

PARTICIPANT

EXERCISE

EXERCISE 2.

INSPECf BURIED PIPELINE, TRANSITION POINTS AND PIPE SUPPORTS

Using the information provided in the work aids and Information section, answer the following questions.

Fill in the blank with the letter of the correct answer or answers.

1. Proper backfilling over buried pipeline is required to

A. Prevent wind and sand erosion of the pipe

B. Ensure product temperatures remain stable

C. Provide identification of the pipeline route

D. Provide protection against vehicle traffic

2. Generally LPG lines, gas lines, and oil well flowlines will have a minimum

ground cover of _

A 1 foot
B. 2 feet
C. 3 feet
D. 4 feet
3. The three types of pipe support are
A. Lowered pipe support
B. Portable pipe support
C. Anchor-type pipe support
D. Raised pipe support 30

PEW 107.02

PARTICIPANT

EXERCISE

4. An area where special emphasis should be placed when excavating

pipelines would be, _

A. Where soil acidity is greater than pH 3

B. Where sub-soil movements are greater than 3 inches a year

C. At low points along the elevation profile of the pipeline

D. Where the water table is less than 1 foot from the ground surface

5. Excavations greater than 4 feet must be shored up or have the side sloped with an angle not exceeding 34 degrees to provide

A. Access to the pipeline

B. Protection against cave in

C. Drainage around the pipe

6. The locations where a pipeline penetrates the ground surface are called

A. Penetration points

B. 51 A Transition points

C. Pipeline points

D. Pipeline right of ways

7. Anchor type supports are most often found where. _

A. Marine vessels load oil for shipment

B. Pipelines cross bodies of water

C. The pipeline needs to be rigidly held in place

D. The pipeline attaches to equipment, branch lines or trunk lines

31

PEW 107.02

PARTICIPANT

EXERCISE

EXERCISE 3.

INSPECf PIPELINE COATINGS

Using the information provided in the work aids and Information section, answer the following questions.

Fill in the blank with the letter of the correct answer or answers.

1. The three primary types of protective coating are _

A. Tape wrapping

B. Heat shrink sleeves

C. Paint

D. FBE

2. Most above ground pipelines _

A. Use tape wrapping as a protective coating

B. Do not have an external coating applied

C. Use heatshrink sleeves as a protective coating

D. Use FBE as a protective coating

3. The primary means of inspecting tape wrapping is _

A. Radiograph

B. Visual

C. UT Meter

D. Window-type test

32

PEW 107.02

PARTICIPANT

EXERCISE

4. The primary means of inspecting FBE-coated pipe is, _

A. Visually

B. UT testing

c. Radiograph testing D. Window type testing

5. Saudi Aramco has phased out, except in minor repairs, the use of _

A. FBE

B. Tape wrap

C. Heat shrink sleeves

6. must not come in contact with hydrocarbons because

hydrocarbons will cause this coating to deteriorate rapidly.

A. FBE

B. Tape wrap

C. Heatshrink sleeves

33

PEW 107.02

PARTICIPANT

EXERCISE

EXERCISE 4.

INSPECT PIPING

Using the information provided in the work aids and Information section, answer the following questions.

Fill in the blank with the letter of the correct answer or answers.

1. The two most obvious signs a buried pipeline is leaking is that the

surrounding area will be saturated with the product and, _

A. a large pressure drop in the pipeline

B. a phosphorescent glow in the soil

C. a noxious odor

O. less than anticipated delivery at the well head

2. PIGs employ either ultrasonic or sensors to perform

inspections.

A. Visual imaging (VI)

B. Particle diagnosis (PO)

c. Magnetic flux leakage (MFL) O. Penetrant analysis (PA)

3. If surface cracking is suspected conduct a of the

pipeline area.

A. Ultrasonic Test «rn

B. Penetrant Test (pn

C. Radiographic Test (RT) O. Revalidation hydrotest

34

PEW 107.02

PARTICIPANT

EXERCISE

4. Large, in-service, valves on pipelines should _

A. Not be radiographed due to the long exposure necessary and poor results

B. Be removed and tested during each inspection

C. Be radiographed to test their condition

D. Be tape wrapped to prevent corrosion

35

PEW 107.02

PARTICIPANT

EXERCISE

EXERCISE 5.

DOCUMENT INSPECTION RESULTS

Using the information provided in the work aids and Information section, complete the fol/owing exercise.

Given the following information, complete a SAF 2643, the Inspection Worksheet. Use the attached SAF 2643 at Figure 9 or one provided by the instructor to complete this exercise. Leave blank any items you do not have information to complete.

Prepare the form using the date 4 July 1994. This is the first worksheet on this project.

You inspected the Abqaiq pipeline from Kilometer marker 10 to 35, 1 July 1994. A work order was issued (Priority C).

The pipeline is buried along the entire length inspected. You conducted a visual inspection.

During the inspection you found a leaking 10" valve at Kilometer marker 22. The valve seems to be leaking around the packing nuts. You found that the berm at Kilometer 30 was damaged due to vehicles crossing the berm. Further investigation shows that this area has become a shortcut between two roads bypassing a constructed crossing between Kilometer 31 and 32.

36

PEW 107.02

PARTICIPANT

EXERCISE

WORKSHEET II BGP ENGINEERING INSPECTION I DATE PREPARED I WORiSHEET NO.
INSPECTION REPORT
Saudi Aramco 2643-ENG (11/90)
EQUIPMENT (NAME) I EQUIPMENT NO. DATE INSPECTED
LOCATION WORK RECOMMENDED BY
INSPECTlON'S SIGNATURE
SERVICE I JOB ORDER
I SUPERVISORS SIGNATURE
FOR I [!] WORK ORDER (ARAMCO 981) ISSUED ON: (DATE)
ACTION I
BY [i] C OPERATORS SlGNATAURE
I x W.O. NO. PRIORITY: COMPL. DATE:
Oparator Indicate action taken, sign and return one copy to Engineering Inspection.
PRIORITY ITEM DESCRIPTION OF WORK TO BE DONE
FORMAT (SCOPE, FINDINGS, CONCLUSIONS, RECOMMENDATIONS)
SCOPE:

FINDINGS:
1
?



CONCLUSION:
1.
2,

RECOMMENDATIONS:
1.
2.



CONTACT: (U ..... vour nam ... )
DISTRIBUTION, CC: Figure 9. SAF 2643

37

PEW 107.02

PARTICIPANT

WORK AID

WORK AID 1.

How TO PREPARE FOR INSPECfION OF ExiSTING PIPELINE PIPING

Use this work aid to guide you in preparing for an inspection and reviewing the proper documents.

Each of these items must be done before the inspection. Mark each item off the checklist as you do them. Make a note of any item you mark no or NIA (not applicable) and the reason. This information may be useful when documenting the inspection.

YES I Items to Check (Check yes or write N/A)
1. Is the Pipeline Data Book available for the inspection?
2. Have you checked Worksheets and Leakage/Repair Reports for
prior problems?
3. Are Pipeline Route Maps of the system to be inspected available?
4. Are Piping and Instrumentation Diagrams of the system to be
inspected available?
5. Is a copy of the SIS in the Pipeline Data Book?
6. Is a copy of the Corrosion Chart Sheet in the Pipeline Data Book?
7. Are Minimum Design Wall Thickness Sheets of the system to be
inspected available?
8 .. Are Scraper Trap Drawings of the system to be inspected
available?
9. Is a copy of the OSPAS Valve List in the PiQ_eline Data Book?
10. Do you have necessary copies of the codes and standards?
11. Have you checked the equipment or project location?
12. Have you ensured that you know the location of the job site and
how to get there?
13. Have you verified that all tools necessary to complete the
inspections are at hand? 38

PEW 107.02

PARTICIPANT

WORK AID

WORK AID 2.

HOw TO INSPECT BURIED PIPELINE, TRANSITION POINTS AND PIPE SUPPORTS

This work aid will assist you in inspecting buried pipeline, transition points and pipe supports. This checklist is only a memory aid. It is not the standard. Refer to the appropriate standards in all cases.

Place a check mark (or X) by items as you inspect them. Items not pertaining to this particular inspection are marked NIA (not applicable). You should consider as unsatisfactory any items that fail. Any items that fail the inspection will require an action. List these items in the inspection report with location, recommendations, corrective action and standards applicable.

PASS FAIL Items to Check (Check pass or fail, or write N/A)
1. Are all crossings properly marked according to SAES-8-064? Ins ctl

oe Ion 0 une rpe mes
PASS FAIL Items to Check (Check pass or fail, or write N/A)
2. Is the buried pipeline in place and not pushing up the
backfill? (loop-out)
3. Is the actual depth of pipeline cover sufficient and does it
conform to the requirements of SAES-L-051?
4. Have the excavations been done properly and in
accordance with GI 434.000?
a. Has the Bellhole been excavated properly?
b. Is there a 16 inch clearance around the pipe?
5. Does the excavated pipe show any signs of deterioration? f B . d P' r

39

PEW 107.02

WORK AID

PARTICIPANT

ection of Transition Points

PASS FAIL Items to Check (Check

Je on 0 I oe uppo
PASS FAIL Items to Check (Check pass or fail, or write N/A)
10. Inspect pipe supports, note any signs of damage, such as
corrosion, abrasion and cracking where the pipe surface is
touching the support
11. Ins_pect the sQacing_ and alignment of pipe supports.
12. Ins_pect the concrete for cracking or spalling.
13. Check the pipe sleeve on anchor type supports to ensure
the pipe has free movement for expansion and
contraction.
14 Verify that the weep hole on the pipe sleeve is not
blocked and that moisture can escape.
15. Check raised-type supports to ensure that the pipe rest in
its support and that the support is correctly aligned.
16. Have the types of permanent pipe supports identified in
the specifications been installed at the proper locations? Ins cti

6. Does the pipeline coating at the transition point show any s s of deterioration?

7. Does the pipe show any signs of corrosion at the transition

nt?

8. Have you verified that there are no leaks indicated by the fo II owi thi

- Pools of liquid

- Stains or discoloration of pipeline coating

- Discoloration in the earth under or in the area around

ine

of deterioration?

f p. S

rts

40

PEW 107.02

PARTICIPANT

WORK AID

WORK AID 3.

HOW TO INSPECf PIPELINE COATINGS

This work aid will assist you in inspecting pipeline coatings.

Place a check mark (or X) by items as you inspect them. Items not pertaining to this particular inspection are marked NIA (not applicable). You should consider as unsatisfactory any items that fail. Any items that fail the inspection will require an action. List these items in the inspection report with location, recommendations, corrective action and standards applicable.

PASS FAIL Items to Check (Check pass or fail, or write N/A)
1. Is the coating/wrapping type as specified in the pipeline
data book? Ta W

~e ra p
2. Are there signs of tape wrap disbondment, such as bulging
and wrinkles on the tape surface?
3. Are there any inconsistencies in the tape? Surface
deterioration may indicate that the tape is allowing
moisture to contact the piping.
4. Inspect for any leaks of fluid through the tape that would
indicate a major failure of the coating.
5. Inspect for any unnoticeable disbondment. Perform a
window test of wrapped piping. Does the coating pass the
adhesion test? If the tape wrap fails the window test, or
corrosion is present under the window, conduct other
tests at different lntervals along the pipe to determine the
extent of the problem. 41

PEW 107.02

PARTICIPANT

WORK AID

Heatshrink Sleeves

6. Is the heatshrink sleeve smooth and free of voids or air
pockets?
7. Inspect the backfill surrounding the heatshrink sleeve. It
must not contain any form of hydrocarbon contamination,
otherwise the heatshrink sleeve breakdown rapidly.
8. Perform a window-type patch test on areas of the heat
shrink sleeve suspected of damage. All damaged areas
shall be cut out and repaired. Ext

IF· b d dE

(FBE) C f

ema usion- on e :poxy oa mg
9. Inspect the epoxy coating. Does the coating show signs of
disbondment, blistering, flaking, and mechanical damage,
such as cuts spalling and abrasion? 42

PEW 107.02

PARTICIPANT

WORK AID

WORK AID 4.

HOw TO INSPECT PIPING

This work aid will assist you in the inspection of the pipeline piping.

Place a check mark (or X) by items as you inspect them. Items not pertaining to this particular inspection are marked NIA (not applicable). You should consider as unsatisfactory any items that fail. Any items that fail the inspection will require an action. List these items in the inspection report with location, recommendations, corrective action and standards applicable.

PASS FAIL Items to Check (Check pass or fail or write N/A)
1. Conduct a visual inspection of the pipeline? Note any areas
of corrosion or damage to the pipeline. Mark corrosion on
the pipeline so that you can determine if it needs to be
repaired or reQlaced.
2. Inspected all pipeline joints and valves for leakage and
damage.
3. Was there an intelligent scraper inspection of the pipeline?
Have the results of the inspection been analyzed? Are
there any problems indicated by the scrapper inspection?
4. Compare the corrosion damage on the pipeline with the
minimums prescribed in the corrosion chart sheets.
5. Determine the condition of the pipeline section by
section. 43

PEW 107.02

PARTICIPANT

WORK AID

WORK AID 5.

HOw TO DOCUMENT INSPEGION RESULTS

Use this work aid as a guide to recording and reporting results of a piping inspection.

Immediately inform your supervisor of anything requiring immediate attention that you discovered in your inspection.

SAF 8213

Fill out the SAF 8213. See Figure 10. The numbers in Figure 10 correspond to the numbers below.

(1) Enter the name and address of the person and division the report is

going to.

(2) Enterthe BI and JO number. (3) Enter the project title.

(4) Enter the report number of this report. (5) Enter the job location.

(6) Enter the plant number or equipment number. (7) Enter the date of the inspection.

(8) Enter any information relevant to the inspection. Include any problems and corrections.

(9) Enter your name, date, telephone number, and signature.

44

PEW 107.02

PARTICIPANT

WORK AID

PROJECTS INSPECTION REPORT

SECTION: _

FAX:

Plant NoJEquip. No.

6

8

Inspector (9) Date Tel. No. Signature
Supervisor Date Tel. No. Signature cc:

Figure 10. SAF 8213 -ENG

45

PEW 107.02

PARTICIPANT

WORK AID

Inspection Worksheet (Saudi Aramco Form 2643)

Fill out the Inspection Worksheet (SAF 2643). Follow the steps in the table and enter the data as indicated in the block entitled "Entry Required." Issue Worksheets to Operations and Maintenance for any unacceptable conditions found and provide the necessary recommendations within. Figure 11 illustrates the numbered blocks that match the steps in the following:

Date the form was typed Next consecutive number assigned by the unit

Function or process name of the equipment assigned by

engineers

The tag number

The date equipment was inspected

Engineering plant name and number

Signature of inspector, supervisor and operator

The kind of product that is handled

Job order and budget item number

Entered by authorized

operator

11. WORK ORDER (ARAMCO 981) An "x" and date if a work order

ISSUED ON (DATE) is issued

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

INFORMATION TITLE

ENTRY REQUIRED

DATE PREPARED

WORKSHEET NO.

EQUIPMENT (NAME)

EQUIPMENT NO.

DATE INSPECTED

LOCATION

WORK RECOMMENDED BY:

SERVICE

JOB ORDER

FOR ACTION BY:

46

WORK AID

PEW 107.02 PARTICIPANT

ENTRY REQUIRED The work order number

The priority of the work order Completion date if one was initiated

Priority, if any before each numbered "ITEM" block

Consecutive numbers vertically for each item of work to be

done

Write in the statements listed under "INFORMATION TITLP' in steps 17a through 17e and

fill in the information as instructed.

Enter job title of the addressee of the report.

Short description of purpose for the inspection

Information necessary Discrepancies found

Make a recommendation as to repairs. They should be

numbered and correspond to findings

"When work commences" put your name and number here.

List personnel by title who will receive the report.

File these reports with the Inspection Department.

12.

STEP INFORMATION TITLE

13.

14.

15.

16.

17.

17a.

17b.

17c.

17d.

17e.

18.

19.

W.O. NO.

PRlORl1Y:

COMPL. DATE:

PRIORITY

ITEM

DESCRIPTION OF WORK TO BE DONE

FOR ACTION BY:

SCOPE:

BACKGROUND:

FINDINGS:

RECOMMENDATIONS:

CONTACT:

DISTRIBvrION, CC

47

PEW 107.02

PARTICIPANT

WORK AID

WORKSHEET " BGP ENGINEERING INSPECTION I DATEP(DED I WORKmNO
Saudi Aramco 2643·ENG (11/90) INSPECTION REPORT
EQUIPMENT (NAME) (3) I EQUIPMENT NO. (4) DATE INSPECTED _(5)
LOCATION (6) WORK RECOMMENDED BY
INSPECTION'S SIGNATURE
SERVICE (s) I JOB ORDER (9) 0)
@l J.0 SUPERVISOR'S SIGNATURE
FOR I 0 ORDER (ARAMCO 981) ISSUED ON: (DATE) 0
ACTION I ill PRIORITY:_@_ COMPL. DATE: ®
BY I Di12 O. OPERATOR'S SIGNATAURE
0
Operator Indicate action taken, sign and return one copy to Engineering Inspection.
PRIORITY ITEM DESCRIPTION OF WORK TO BE DONE
05) 06) (17)

EQ8 AQIIQ~ BY; G 7;;;


SQQee; (17~



BAQ~!a8Q!.1~Q ~ (17~


EIt::!QIt::!GS; (17~


BEQQMMEt::IOAIIQt::IS' G 7~






QQt::!TAQI; (18) " WHEN WORK COMMENCES "


DISTRIBUTION, cc . (19) Figu re 11. Worksheet with n u mbe red data blocks

48

PEW 107.02

PARTICIPANT

GLOSSARY

isolation valves

Anything attached to the pipeline including valves, brackets, and supports.

Concrete that is easily crumbled or pulverized.

Valves that can be used to completely shutdown the flow of a product to a segment of pipeline, thus isolating it for repair or inspection.

appurtenances

friable

jurisdiction

mothballed

Who specifically has responsibility for the maintenance and inspection of the particular segment of pipeline.

Spalltng is a form of concrete deterioration caused by heat or an insufficient thickness of concrete over the reinforcement Cracks develop, allowing moisture to enter and attack the steel reinforcement Corrosion products build up and exert pressure against the concrete. The concrete flakes or spalls, exposing the reinforcement to further attack. Only a visual inspection is necessary to detect this type of deterioration.

No longer used operationally, but maintained in a state that would allow it to be used again, if necessary.

spalling

49

PEW 107.02

PARTICIPANT

EVALUATION

Using the information provided in the work aids and Information sheets, answer the following questions.

Fill in the blank with the letter of the correct answer or answers.

1. The P&IDs provide information on _

A Coatings

B. Previous UT thickness measurements

C. Valves and junctions

D. Previous inspections

2. The most important single piece of information about the pipeline is the

A P&IDs

B. Pipeline Route Maps

C. SIS

D. Corrosion Chart Sheets

3. The three permanent types of pipe support are:. _

A Lowered pipe support

B. Portable pipe support

C. Anchor-type pipe support

D. Raised pipe support

50

PEW 107.02

PARTICIPANT

EVALUATION

4. All pipelines and crossings will be marked according to _

A SAES-H-203

B. Local custom

C. SAES-B-064

D. SAEP-20

5. Anchor type supports are most often found where _

A Marine vessels load Oil for shipment

B. Pipelines cross bodies of water

C. The pipeline needs to be rigidly held in place

D. The pipeline attaches to equipment, branch lines or trunk lines

6. Pipeline loop-out can be prevented by _

A Reducing the angles of the pipe

B. Reducing the pressures in the pipeline

C. Proper ground cover

D. Increasing the diameter of the pipe

7. Corrosion chart sheets provide information on _

A Operation of the D-meter

B. Protective coatings type and depth

C. Test point locations and remaining life of the pipe

D. Acceptable limits of corrosion metal loss

51

PEW 107.02

PARTICIPANT

EVALUATION

8. During analysis.

the

scraper

inspection

the frrrata lates

sto rE

A. On paper

B. In the inspection department

C. In a dry, cool, lightless environment

D. On computer tape or disk

9. When conducting a window-type patch test of tape wrap you are

primarily ensuring that _

A. The tape pulls away cleanly leaving no particles still attached to the pipe

B. There was 100% adhesion of the tape sample with the surface of the pipe

C. The tape does not crumble and indicate signs of brittleness

D. The pipe beneath the tape sample has been coated with FBE prior to wrapping

10. The primary means of inspecting FBE-coated pipe is _

A. vlsuallv

B. UT testing

c. Radiograph testing D. Window type testing

52

PEW 107.02

PARTICIPANT

EVALUATION

11. Excavations greater than 4 feet will be shored up or have the side sloped

with an angle not exceeding 34 degrees to provide _

A. Access to the pipeline

B. Protection against cave in

C. Drainage around the pipe

12. Inspection of S/A transition points are critical because _

A. They are the most susceptible to coating failure and corrosion damage due to soil stresses and moisture accumulation

B. Isolation valves located at these transition points have a short life expectancy

C. Pipeline movement at these points cause abrasion to the pipe and thus shorten the operational life

13. The primary problem with tape wrap has been, _

A. Blistering

B. Disbonding

C. Cracking

D. Faking

14. Valves are classified according to' _

A. Size

B. Weight

C. The amount of product that can flow through them in a specified time period

D. The pressure they can stand

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Given the following information, complete the SAF 2643 at Figure 12. Include recommendations for repair, if any are necessary. Leave blank any items where there is no information to complete.

BI/JO number G-3232. Abqalq pipe line.

Job location-Kilometer 10 to Kilometer 35. Prepare the form using the date 4 July 1994.

You inspected the Abqaiq pipeline from Kilometer marker 10 to 35, 1 July 1994. A work order was issued (Priority C).

The pipeline is buried along the entire length inspected. You conducted a visual inspection.

During the inspection you found a leaking 10" valve at Kilometer marker 12. The valve seems to be leaking around the packing nuts. You found that the berm at Kilometer 30 was damaged due to wind erosion. Kilometer marker 30 and 31 have been destroyed by what appears to be vehicle damage. A vehicle crossing is located at Kilometer 31.

Use your name as the inspector, date 6 July 1994, telephone number 321-3214.

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PAGE_ OF

WORKSHEET II BGP ENGINEERING INSPECTION I DATE PREPARED I WOR~SHEET NO.
INSPECTION REPORT
Saudi Arameo 2643·ENG (11/90)
EQUIPMENT (NAME) I EQUIPMENT NO. DATE INSPECTED
LOCATION WORK RECOMMENDED BY
INSPECTION'S SIGNATURE
SERVICE I JOB ORDER
I SUPERVISOR'S SIGNATURE
FOR I [!] WORK ORDER (ARAMCO 981) ISSUED ON: (DATE)
ACTION I
BY GJ C OPERATOR'S SlGNATAURE
I X W.O. NO. PRIORITY: COMPL. DATE:
Operator indicate action taken, sign and return one copy to Engineering Inspection.
PRIORITY ITEM DESCRIPTION OF WORK TO BE DONE
FORMAT (SCOPE, FINDINGS, CONCLUSIONS, RECOMMENDATIONS)
SCOPE:

FINDINGS:
1
?



CONCLUSION:
1.
2.

RECOMMENDATIONS:
1.
2.



CONTACT: (II .. " vnlJ~ "am,,)
DISTRIBUTION, CC: Figure 12. SAF 2643

55

ADDENDUM A

STANDARDS TO INSPECT EXISTING PIPELINE PIPING

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ADDENDUM

INSPECTION Sf ANDARDS

These documents provide the instructions for inspections necessary on pipelines and components.

o SAES-A-OOS, Safety Instruction Sheet (SIS)

o SAES-B-064, Onshore and Nearshore Pipeline Safety

o SAES-H-002, Internal and External Coatings for Steel Pipelines and

Piping

o SAES-H-100, Painting Requirements for Industrial Facilities

o SAES-H-102, Safety Requirements for Painting

o SAES-H-200, Storage, Handling, and Installation of Pipe Externally Coated with Fusion-bonded Epoxy or Polyethylene

o SAES-H-201, General Specification for Over-the-ditch External FBE Coating of Field Girth Welds

o SAES-H-203, Hand-applied Tape Wrapping of Buried Pipe

o SAES-H-204, General Specifications for Applying Heat-shrink Sleeves to

Coated Pipe

o SAES-L-020, Design of Transportation Piping Systems

o SAES-L-OS1, Construction Requirements for Cross-country Pipelines

o SAES-W-001, Basic Welding Requirements

o SAES-W-012, Welding Requirements for Pipelines

o SAD P-W-OO 1 , Welding Requirements and Procedures

o GI 434.000, Pipeline Repair and Maintenance

o GI-44S.001, Performance Qualification of Critical Personnel

c 09-AMSS-089, Shop-applied External FBE Coating

o API RP*S74, Inspection of Piping, Tubing, Valves and Fittings

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SAES-A-005

Safety Instruction Sheet

This standard outlines the procedure to be followed in the preparation of equipment Safety Instruction Sheets (SIS), Aramco form 2694. This standard contains the following information:

o Scope

o Purpose

o Preparation

e Approval

o Control

o References

SAES-8-064

Onshore and Nearshore Pipeline Safety

This standard covers safety requirements for onshore pipelines and submarine pipelines nearshore. These include, but are not limited to, cross-country pipelines, flowlines, trunklines, tielines, water injection lines, gas lift lines, and test lines.

o Scope

o Conflicts and deviations

o Applicable codes and standards

o Pipeline location classes

o Rupture exposure radii

o Population Density analysis

o Pipeline location classification

o Design pressure

o Scraper launcher and receiving installations

o Pipeline corridors

o Pipeline valves

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SAES-H-002

Internal and External Coatings for Steel Pipelines and Piping

This standard gives the mandatory internal and external coating selection requirements for steel pipelines and piping (including associated fittings and appurtenances) and the mandatory performance requirements of these coatings. Excluded from this standard are temporary coatings. This standard does not preclude the use of galvanized, alloy, or nonmetallic pipe where allowed by other Aramco standards.

e Scope

o Conflicts and deviations

o Applicable codes and standards

o Definitions

o Selection requirements

o Product/Performance Data Sheets for Approved Aramco Pipe Coating Systems

SAES-H-100

Painting Requirements for Industrial Facilities

This standard prescribes the minimum painting requirements for the corrosion protection of industrial facilities in onshore, offshore, atmospheric, and/or immersion services. This standard contains the following information:

o Scope

o Conflicts and deviations

o Applicable standards

o Safety

o Surface preparation

o Paint, storage

o Paint, preparation

o Paint, application

o Quality control

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SAES-H-102

Safety Requirements for Painting

This standard prescribes the minimum safety requirements applicable during shop or field painting for new construction, maintenance, and/or repair of Aramco industrial facilities and equipment. This standard contains the following information:

o Scope

o Conflicts and deviations

o Applicable codes and standards

o Safety requirements

SAES-H-200

Storage, Handling, and Installation of Pipe Externally Coated with Fusion-bonded Epoxy or Polyethylene

This standard covers the mandatory requirements governing the storage, handling, and installation of linepipe and piping that have been externally coated with shop-applied fusion-bonded (FBE) or polyethylene (PE) coating.

o Scope

o Conflicts and deviations

o Applicable codes and standards

o Definitions

o Storage, handling and transportation

o Handling

o Inspection and Quality assurance

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SAES-H-201

General Specification for Over-the-ditch External FBE Coating of Field Girth Welds

o Scope

o Conflicts and deviations

o Applicable codes and standards

o Definitions

o Material Storage and handling

o Design

o Installation

o Inspection Methods and Acceptance Criteria

SAES-H-203

Hand-applied Tape Wrapping of Buried Pipe

This standard gives the mandatory requirements for the storage, handling, and application of hand-applied pipe wrapping tape described in AES-H-002, APCS-107, "Pressure-sensitive, Hand-applied Tapewrap for Temperatures up to 55°C" and in AES-H-002, APCS-109 "Pressure-sensitive, Hand-applied Tapewrap for Elevated Temperatures Service."

o Scope

0 Conflicts and deviations
0 Definitions
0 Material Storage and handling
0 Surface preparation
0 Primer application
0 Tape application
0 Outerwrap application
0 Safety requirements
0 Repairs
0 Inspection
0 Handling coated pipe
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SAES-H-204

General Specifications for Applying Heatshrink Sleeves to Coated Pipe

This standard covers mandatory requirements governing the storage, handling and installation of heat-shrink sleeves used for coating the field girth weld area of externally coated pipe. The external pipe coating may be fusion-bonded epoxy, polyethylene, or hot-applied coal tar enamel.

e Scope

o Conflicts and deviations

o Applicable codes and standards

o Definitions

o Material Storage and handling

o Design

c Installation

o Inspection Methods and Acceptance Criteria

SAES-L-020

Design of Transportation Piping Systems

This standard contains general system design requirements for cross-country and offshore transportation piping, common to all pressure services, and supplementing the ANSI/ ASME Code.

o Scope

o Applicable code section

o Design package and project records

o Pipe size

o Routing and type of installation

o System appurtenances

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SAES-L-OS1

Construction Requirements for Cross-country Pipelines

This standard covers construction requirements for steel cross-country pipelines, aboveground or buried, restrained or unrestrained, in all services. Offshore pipelines and non-metallic pipelines are not covered by this standard.

o Scope

o Vertical profile

o Storage and handling

o Installation of aboveground pipelines

o Installation of buried pipelines

o Tie-in temperatures

o Clean-up, records

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SAES-W-001

Basic Welding Requirements

This standard specifies the minimum requirements for the shop and field fabrication, repair, or modification of pipelines. This standard contains the following information:

o Scope

0 Conflicts and deviations
0 Approved welding processes
0 Welding consumables
0 Welding procedure qualifications
0 Joint design
0 Technique and worKilometeranship
0 Preheat
0 Post weld heat treatment
0 Weld hardness testing
0 Inspection access
0 Quality control
0 Inspection
0 Repairs
0 Specific applications 64

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SAES-W-012

Welding Requirements for Pipelines

This standard specifies the minimum requirements for welding cross-country pipelines to ANSI B31.4 and B31.8. This standard contains the following information:

0 Scope
0 Conflicts and deviations
0 Processes
0 Joint design
0 Qualifications
0 Inspection
0 Preheat and Post weld heat treatment
0 Technique and worKiiometeranship SADP-W-001

Welding Requirements and Procedures

This Saudi Aramco Design Practice provides background information and outlines engineering considerations to aid engineers, designers, and inspectors in understanding and implementing the mandatory requirements of welding standards. This design practice contains the following information:

o Scope

o Applicable documents and references

o Welding processes

o Welding consumables

o Welding procedure qualifications

o Welders and welding operators performance qualification

o Welding design details

o Preheat and Post weld heat treatment

o Hardness testing

o Inspection

o Specific welding applications

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G1434.000

Pipeline Repair and Maintenance

This instruction describes procedures to be followed in repair and maintenance of onshore pipelines. This instruction contains the following information:

o References

o Safety, general

o Precautions against electric shock when working on existing pipelines,

extensions, operations and maintenance

o Reconditioning of buried pipelines

o Pipe repair procedures

o Welding

o Inspection and testing of pipeline repairs

o Offshore submarine pipelines

G1445.001

Performance Qualification of Critical Personnel

This instruction describes the performance qualification requirements for all personnel associated with Saudi Aramco critical coating work, and is administered by the Inspection Services Division, CSD.

o Scope

o Definitions

o General requirements

o Qualification procedure and test requirements

o Qualification documentation and records

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09-AMSS-089

Shop-Applied External FBE Coating

This specification covers the minimum requirements of fusion-bonded epoxy powder coating for the external surface of line pipe. This specification contains the following information:

e Scope

o Ordering information

o References

o Materials

o Cleaning and surface preparation

o Coating application

o Quality requirements

o Inspection requirements

o Recheck on coating material qualities

o Repairs

o Pipe storage and preparation for shipment

API RP*S74

Inspection of Piping, Tubing, Valves and Fittings

This recommended practice covers inspection of piping, tubing, valves, and fittings used in refineries. This standard contains the following information:

o Scope

o Piping Components

o Reasons for Inspection

o Frequency and Time of Inspection

o Safety Precautions and Preparatory Work

o Inspection Tools

o Inspection Procedures

o Determination of Retirement Thickness

o Records

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