Inspection Procedure

00-SAIP-73 Inspection Manning Determination Guidelines Document Responsibility: Inspection Department 26 October 2005

Saudi Aramco DeskTop Standards
Table of Contents

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Scope............................................................. 2 Definitions...................................................... 2 Responsibilities.............................................. 3 Instructions..................................................... 3 Methodology................................................... 4 Other Factors Affecting Manpower Determination....................... 6 Datasheet Population..................................... 6 Calculation Module........................................ 8

Attachment I – Data Entry/Output Form............... 9

Previous Issue: New

Next Planned Update: 1 November 2010 Page 1 of 9

Primary contact: Nasser M. Balhareth on 874-5018

Commentary Note: The Non Work-Available Calendar Man-Hours (NWACMH) is based on input from practicing inspection personnel. For this module. Non Work-Available Calendar Man-Hours (NWACMH): The time lost on vacations (176 Mhrs/yr) medical appointments (32 Mhrs/yr). a power boiler is the largest plant equipment.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines 1 Scope This Saudi Aramco Inspection Procedure (SAIP) provides guidelines for estimating the optimum manning levels of the plant inspection units (PIUs). The model makes some approximations such as that all manpower is Aramcons and Muslims which reduces their work-available man-hours. Effective Man-Hours (EMH): The Man-Hours that can be dedicated for inspection related activities. This is equal to 1372 man-hours. rescheduled days-off (80 Mhrs/yr). breaks (260 Mhrs @ 1 hrs/day). 2 Definitions Inspection Unit Time (IUT): A unit of time required to conduct a single thorough inspection on the largest plant equipment in a facility. Work-Available Calendar Man-Hours (WACMH): The total calendar man-hours (TCMH) minus the Non Work-Available Calendar Man-Hours (NWACMH). Facility Condition Factor (FCF): A correction factor to get the optimum manning level within an inspection unit. Ramadan (40 Mhrs/yr). The TCMH used for calculations in this module is 2080 Mhrs/year. the unit average direct inspection experience level and the facility's use of a management of change program. The NWACMH used for calculations in this module is 708 Mhrs/year. The effective Man-Hours are a function of the direct inspection experience level and the Work-Available Calendar Man-Hours. The FCF is a function of the average plants age. Approved Unit Full Jobs: These are approved budget slots for the unit in the department's organization structure. and the unit of time equals three hours. These correspond to specific job codes in a job ladder of a job family. Required Man-Hours (RMH): The calculated inspection eman-hours required by a given inspection unit to provide the needed inspection coverage for routine and T&I related activities by each inspection group. The approved full jobs are used for analytical purposes only in Page 2 of 9 . Total Calendar Man-Hours (TCMH): The calendar year man-hours based on a 40hrs/week work schedule per person. occasional absence (40 Mhrs/yr). This procedure can be used by either the Inspection Department when conducting the plant inspection unit assessment or the plant inspection units when assessing their manpower needs. training (80 Mhrs/yr). It provides a consistent measure for level of manning in PIUs.

Chronic Medical Condition (CMC) cases and transfers.5 The various inspection programs administered by an inspection unit. 3. The number of issued versus open work sheets.3 4.2 PIU supervisors are responsible for anticipating and providing manpower forecasts in their departments' business plans to offset manpower attrition due to retirement. etc.2 3.2 Elec. 9-10.1 Provide adequate inspection coverage to all plant areas and support facilities within their responsibility as defined in SAEP-20 and SAEP-309 respectively. 13) within an inspection discipline or work group (PE&W. Civil. Grade Code Group (GC): A Grouping of Grade Codes (GC7-8.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines comparison to the optimum manpower and the existing manpower.4 4.1 4.1 The data required for manpower determination includes but not limited to: 4.. This grouping is used to simplify the breakdown of inspectors within a discipline or a group for ease of calculation of the average experience level and manhours per discipline or group. Establish. The frequency of T&Is in relation to the number of static plant equipment. Page 3 of 9 .1.1 It is the responsibility of the operating organization management to ensure that their plant inspection units (PIUs) are sufficiently manned with qualified manpower to: 3. etc. 11-12.1.1.) within an inspection unit. and a full or part time dedicated training coordinator (based on PIU size) to ensure that development. They are not used in the calculations. maintain.3 3. The level of direct inspection experience of each grade code (GC) group within an inspection discipline in a PIU.1. The facility remoteness from inspection offices.1. Ensure that inspection programs are properly and efficiently administered.4 3. Conduct self assessments of the various inspection programs to maximize the return from such programs. This should include a corrosion control / cathodic protection engineer. 3 Responsibilities 3. 4 Instructions 4. training and certification needs of inspection personnel are properly addressed. administer and optimize other inspection and corrosion control programs such as relief valves administration and OSI.

2 The average facility age and whether the facility has a documented and effective management of change procedure.3 4.. particularly if a three 8-hour. The module estimates the manpower needs for each discipline (i. mechanical. 7 or 10-year T&I's that occur within any calendar year should include man-hours needed.1. these facilities should rely on manpower support during T&I from other plants. civil. For optimum manning. electrical. Facilities that conduct their T&I's on the bases of total facility shutdown at fixed intervals (5. an inspector will need to conduct at least two thorough inspections and three follow-up inspections.1 The module is designed to estimate the man-hours needed to provide inspection coverage on day-to-day activities and during major shutdowns and T&I's per calendar year and compare it to the Work Available Man-Hours (WAMH) per inspection group. For this exercise. 4. Instead.1. a power boiler is considered the largest piece of equipment in Saudi Aramco facilities that requires an average of three hours for a single comprehensive inspection on all of its components. Facilities which frequently have a number of 5.7 4.4 5 Methodology 5.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines 4. each inspection activity / equipment type is assigned a Page 4 of 9 5. It is also estimated that during T&Is and routine worksheet related inspections.6 4. or two 12hour shift system is used to provide coverage on a 24-hour basis. the excel program estimates the variance between the Work Available Man-Hours and the Required Man-Hours and converts the variance into manpower figures. The variance is converted to excess or additional manpower per each inspection group and the optimum unit overall manning level exclusive of the unit supervisor is determined accordingly. To account for the difference in the size of equipment and the extent of the required inspections. such facilities should not be manned for an activity that takes place once every 5 or 7 years.3 .) and indicates whether there is a deficiency or excess in manpower. 7 or 10 years) should not include man-hours needed for the purpose of the T&Is in the overall manpower calculations. contractors or Inspection Department. The contribution of the unit's personnel to non-core inspection activities such as special projects.e. The module utilizes an experience-based estimate of the amount of time it takes an inspector to conduct a single thorough inspection on the largest piece of equipment in the facility and the number of inspections conducted on the same equipment for the same purpose. The frequency and extent of on-stream inspection programs inclusive of special surveys.2 5.8 4. etc.1. and support to other organizations. Upon filling the excel spreadsheet with the required data.

333 (20 minutes / RV) plus the result of the total number of RVs divided by 2 multiplied by 0. the WACMH for inspectors in an inspection group is multiplied by the average of direct inspection experience for a grade code group (GC 7-8.8 for a tall trayed column.5 The other side of the calculation is based on the effective man-hours (EMH) concept.6 To determine the EMH of the various inspection personnel. 13) within an inspection group (PE&W.) 5.7 for a sphere. etc. Hence.. the number of equipment or activity is divided by its frequency of inspection (T&I cycle) to get the annual figure. Civil. to determine the Man-Hours required for conducting inspection on relief valves (RVs) by a dedicated RV administrator. for determining the man-hours required for a certain type of equipment or activity. 9-10. their EMH is considered lower than their WACMH. 5.e.6 for a pressure vessel. 0. For example. etc. 0.1 Manpower determination is affected by the remoteness of facilities covered by a given inspection unit. and the predetermined inspection unit time of 3 hours. As a rule of thumb. then the number is multiplied by its assigned inspection unit time weight factor. on the other hand. and the condition of the facilities under inspection in Page 5 of 9 . 11-12. 0.167 (10 minutes / RV) if the administrator is also conducting the external inspection of the RVs as well. the number of inspections required. The direct inspection experience level of inspection personnel and the Work Available Calendar Man-Hours (WACMH) are the two variables governing this calculation. Elec. junior inspectors spend more time on handling a certain inspection activity and on training assignments than senior inspectors. Field supervisors and senior inspectors.: 1 for a power boiler.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines weight factor to determine the percentage of Inspection Unit Time (IUT) spent during a single inspection.). the result of the external RVs inspection is added to the mechanical inspection required man-hours for the plant equipment / welding inspectors. Otherwise. For example. 6 Other Factors Affecting Manpower Determination 6. (i. should have mastered their inspection tasks and should have completed most of their training needs which makes their EMH closer to their WACMH. The calculated EMH for the inspection group is then compared to the RMH of the group and the result indicates whether additional man-hours are needed or excess man-hours are available.4 The required man-hours for all inspection activities is determined in a similar fashion with the exception of activities requiring single inspections where the amount is multiplied by a pre-determined quantity (number) of inspection time required for such activities. 5. the total number of RVs is divided by their T&I interval to obtain the annual number and the result is multiplied by 0.

60~84. the equipment are broken down to four T&I cycle groups (12~24. & 120 months).5.e.: 1. 6 and10 years). draftsmen. and average years of direct inspection experience. to the Total Unit RMHs. exclusive of over time and travel time. The datasheet is divided into eleven main fields each containing several sub-fields. one (1) hour of travel time per 50 km or a constant eight hours for flying is multiplied with the group's share of the open and closed worksheets and the result added to the Required Man-Hours (RMH) for each group. For ease of calculations. To ensure that the sheet is user friendly. In calculating the required Man-Hours. and whether the facility has an effective management of change. 3. Page 6 of 9 2. Manpower: This field includes a break down of available manpower by discipline.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines terms of their age and whether the facility has an effective management of change procedure. Each equipment type is assigned a weight factor related to its size and the inspection time it takes.4 7 Datasheet Population The performance of the calculation module is dependant on the accurate population of its data sheet. and whether the facility is implementing a written and effective Management of Change (MOC) procedure. Equipment: This field provides an account for all static plant equipment subject to T&I. A Facility Condition Factor (FCF) has also been introduced to account for the facility age. inspection expertise. 6. 36~48. This factor is multiplied with the variance in manpower for each inspection group to get the optimum manpower level required for that inspection group. Round trips as well as the number of inspections spent on open and closed worksheets are considered in the calculation. Operating Information: This field includes plant data such as facility age. Information in this field coupled with the calculated inspection Unit experience level is essential for determining the Facility Condition Factor (FCF) required for calculating the optimum manning level. the average T&I cycle is used (i. A brief description of the main fields is provided below: 1. 3. The overtime spent on non-T&I / major shutdown related activates will be directly added to each group's RMH based on the ratio of the group's RMH. Individuals such as training coordinators. directive comments are posted in all data fields. 6.3 6. The facility age is an arithmetic average of the age of all plants within the facility. .2 For PIU's covering remote facilities to offset the time spent on travel. operating practices.5. The overall experience level within an inspection unit also affects the calculation. grade code. clerks as well as permanently or temporally assigned engineers who are not directly involved in providing direct inspection coverage or the administration of other inspection or corrosion control programs are not included in this module.

For the purpose of calculation. OSI. civil as well as corrosion control programs related data are provided under this field. The overtime hours is added to the group needed man-hours based on the ratio of the group required man-hours to the overall unit required manhours. Worksheets / Year: The number of issued and closed worksheets in a calendar year is specified in this field. In both cases the round trip is also considered. 6. The travel time is a function of the number of open and closed worksheets multiplied by the number of inspections conducted at a ratio of 1hr/50km. Inspection Programs: All data related to inspection programs such as external inspection. 7. Comments are provided at each program section explaining how the data is used for the different inspection groups and the time it takes to complete each inspection activity. 8 Calculation Module Page 7 of 9 . 8. Design Review Packages: All engineering design packages that undergo inspection review are broken down in this field. Travel Distance: This field is provided for inspection units that provide inspection coverage to areas not within one fence such as the case for producing and distribution facilities. 10. Approved Unit Full Jobs: The approved unit full jobs are listed under this field for analytical purposes upon comparison of the optimum manpower to the existing manpower.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines 4. 5. electrical. Corrosion Control Programs: All corrosion control programs are included under this field. worksheets are assigned a weight factor of 0. The discipline inspector will on the average dedicate three inspection unit times per worksheet. 9. For flights. Project Support: This field is dedicated for the manpower support to projects provided by the plant inspection unit. Comments are provided at this section for utilization of the man-hours spent on project support with respect to each inspection group. Paid and un-paid overtime shall be considered to give a more accurate reflection of man-hours associated with performing inspection activities. The resulting value is shared by the different inspection groups based on their share of the issued worksheets. Average Total Overtime / Year: The overtime spent by all inspection personnel including contractors is entered in this field to indicate the over utilization of the unit personnel. a constant eight hours is multiplied instead of the ratio. Comments are provided at each section explaining how the data is used and the time it takes to complete them. 11. Comments are provided at this section explaining how the data is used for the different inspection groups and the time it takes to complete packages review.5 of a 3 hours inspection unit times.

Avg.0 Htr.6 0. Experience Civil Inspectors Civil Avg. Data Entry/Output Form for Recommended Manning Calculation Module for Plant Inspecti Inspection Unit Information (1) Operating Example M. Civil Insp.84 120 CUI lo 9 26 1 17 3 0 46 0 0 1 0 0 1108 0 13 0 5 0 0 0 0 32 0 0 0 0 0 93 0 (7) 14 0 208 4 0 0 17 143 190 0 0 65 0 63 0 Issued 18 277 35 0 0 0 15 35 0 0 0 0 0 0 Closed Specia Elec. Expereince Level Total (3) Equipment Avg. 26 October 2005 Attachment I. Others Discipline Electrical GC10 GC11+ Ro 1 1 1 1 Note: All Cells in White Should be filled as appropriate Page 8 of 9 . Experience Plant CC. Electrical Insp. 6.0 U/G H.8 Type Columns T&I Frequency (months) 12-24 Inject Dead 36-48 60 .9 Nippl PE&W Insp.0 8.& CP Engr. 1. 1. Experience Subs Supp RV Inspectors RV Avg. CC& CPAvg. Insp./Cond. (4) 0. Civil 2 7 3 46 9 46 10 6.0 Tanks 10.O.18 R/V Insp.0 Supt. OSI Avg.0 Boilers 7.5 Loadg Fclty. Experience 1 9 1 6 46 8 Misce Supp 6. Valves Misc. CC&CP Avg. Faclty OSI R./Frn.0 7. Elec. 9. Experience (5) Design Pkgs/ yr.4 0. S Trans (6) Approved Unit Full Jobs (9) Project Support Worksheets/ yr 5 Civil 7 GC9 4 11 3 12 Anode 7 Discipline P&E/Welding Corrosion 0 GC9 0 GC10 264 GC11+ (10) 243 Total Over Time/ yr.7 Spheres 2.Inspectors 6.4 Civil Insp. Experience Ext.0 Drums 4. OSI/NDT Insp. The latest calculation program can be downloaded from the Inspection Department website. Revision Summary New Saudi Aramco Inspection Procedure.& CP Insp.49 Unit Avg. Insp. Corro.7 Corr.C Used Date Prepared % over Design Capacity 5 Facility Age (yrs) No Current Required OSI / NDT Related 5 Manpower 7-8 9-10 11-12 32 13 (2) Discipline Recommended Manning Levels PE / W Inspection 0. 1. Corrosion Control Programs (8) Elec.0 Vessels 11. Control 8.Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010 00-SAIP-73 Inspection Manning Determination Guidelines The attached Data Entry form is used for collecting the required data for performing the manning calculations.5 years Ins Type OSI TM 27.5 CC. Experience 2 2 3 6 2 6 1 5 1 5 2 4 2 8 2 10 1 9 5 10 1 10 2 10 13 3 15 1 15 1 15 1 14 9. 2 Grade Codes Probe Coupo Pot. Fin Fans Rd Crossing Pipin Relief Plant OSI/NDT Tech.0 Exch.C pip./Flr.5 3. Mech Elec. PE&W Avg.

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