ARAMCO SAIP-80-Process-Equipment-Insp-Guide PDF

Inspection Procedure
00-SAIP-80 26 November 2007

Guidelines for Process Equipment Inspection
Document Responsibility: Inspection Department
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope............................................................. 2
2 Purpose.......................................................... 2
3 Safety............................................................. 2
4 References..................................................... 2
5 Definitions and Abbreviations........................ 4
6 Inspection Guidelines…................................. 7
6.1 Vessels………………............................ 7
6.2 Reactor Vessels…………….……......... 9
6.3 Platformer Reactor Vessel.................. 10
6.4 Heat Exchanger………………............. 12
6.5 Reactor Effluent Heat Exchanger....... 15
6.6 Fin Fan Cooler.……………………...... 17
6.7 Process Heater….……………….....… 20
6.8 Reformer Heater…………………..….. 22
6.9 Industrial Boiler………...…………...… 24
6.10 Tanks………………………......………. 26
Attachment A – Flowchart-Process Equipment

Inspection
Attachment B-I~VI – Typical Inspection Plan
(TIP) for Process Equipment
Attachment C-I~XI – Inspection Checklist
for Process Equipment
Attachment D – Equipment, Nomenclature,
Types and Items for Inspection
Previous Issue: New Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 90
Primary contact: Abdulcader, Seyed Mohammed on 966-3-8747519
Copyright©Saudi Aramco 2007. All rights reserved.

Document Responsibility: Inspection Department 00-SAIP-80
Issue Date: 26 November 2007
Next Planned Update: TBD Guidelines for Process Equipment Inspection
1 Scope
This Saudi Aramco Inspection Procedure (SAIP) establishes guidelines for inspecting
pressurized static process equipment that have been placed in service. This procedure
supplements SAEP-325.
2 Purpose
This SAIP is intended to assist the Plant and Equipment (P&E) Inspectors of Plant
Inspection Units in their selection by providing Typical Plans and inspection checklist
for all types of existing plant equipment, on stream evaluation, and tracking of existing
equipment condition.
3 Safety
3.1 Radiographic examination personnel safety should be per SAEP-1143 paragraph

3 and GI-0150.003.
3.2 All pressure testing should be in compliance with GI-0002.102, "Pressure

Testing Safely".
3.3 Use of personnel protection equipment and safe entry for inspection is the
responsibility of the inspector/Inspection Engineer.
4 References
The following standards were used in the preparation of these inspection guidelines and
should be carefully reviewed by the inspectors/inspection engineers prior to performing
inspection. All references should be the latest issued revision or edition.
4.1 Saudi Aramco References
Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-206 Positive Material Identification
SAES-D-008 Repairs, Alteration, and Re-rating of Process
Equipment
SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-011 Welding Requirements for On-Plot Piping
SAES-W-012 Welding Requirements for Pipelines
SAES-W-014 Weld Overlays and Welding of Clad Materials
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SAES-W-015 Strip Lining Application

SAES-W-016 Weld of Special Corrosion-Resistance Materials
SAES-W-017 Welding Requirement for API Tanks
Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Requirement
SAEP-325 Inspection Requirements for Pressurized
Equipment
SAEP-1140 Qualification and Certification of Saudi Aramco
NDT Personnel
SAEP-1141 Industrial Radiation Safety
SAEP-1142 Qualification and Certification of Non-Saudi
Aramco NDT Personnel
SAEP-1143 Radiographic Examination
SAEP-1144 Magnetic Particle Examination of Welds and
Components
SAEP-1145 Liquid Penetrant Examination of Welds and
Components
Saudi Aramco General Instructions

GI-0002.102 Pressure Testing Safely
GI-0150.003 Radiation Safety
Saudi Aramco Inspection Procedures

00-SAIP-07 Positive Material Identification Requirements
00-SAIP-74 Inspection of Corrosion under Insulation &
Fireproofing
00-SAIP-75 External Visual Inspection Procedure
01-SAIP-01 Small Nipple Inspection Program
01-SAIP-02 Retirement Thickness of In-Plant Piping
01-SAIP-04 Injection Point Inspection Program
32-SAIP-11 Inspection of Air-Cooled Exchangers
Page 3 of 90
4.2 Industry Codes and Standards
American Society of Mechanical Engineers

ASME SEC V Nondestructive Examination
ASME SEC VIII Boiler and Pressure Vessel Code
ASME B 31.1 Power Piping
ASME B 31.3 Chemical Plants and Petroleum Refinery Piping
American Petroleum Institute

API STD 510 Pressure Vessel Inspection Code
API RP 571 Damage Mechanism Affecting fixed Equipment
API RP 572 Inspection of Pressure Vessels
API RP 573 Inspection of Boilers and Heaters
API RP 580 Risk Based Inspection
API RP 578 Material Verification
API STD 620 Design and construction of Large, Welded, Low
Pressure Storage Tanks
API STD 650 Welded Steel Tanks for Storage
API STD 660 Shell and Tube Heat Exchangers
API STD 661 Air Fin-Coolers
API RP 932-B Insp. Guideline for Effluent Air Coolers
NBIC National Board Inspection Code
5 Definitions and Abbreviations
Pressure Vessels: Is a container designed to withstand internal or external pressure.

The vessels are constructed in accordance to ASME Boiler and Pressure Vessel Code,
Section VIII. These vessels are subjected to internal or external operating pressure
greater than 15 lbs/in2. Drums, Towers, Columns and Reactors, heat exchangers,
condensers, air coolers, bullets, spheres and accumulators are common types of pressure
vessels.
Tanks: Tanks are built to API STD 650 covers, fixed roof, floating roof, floating and
fixed roof tanks. The scope is limited to the tank foundation, bottom, shell, structure,
roof, attached appurtenance and nozzles.
Heaters: There are a variety of designs for fired tubular heaters. Some of the
commonly used designs are the box, cylindrical, and cabin types. The tubes in the
Page 4 of 90
radiant are called radiant tubes. The heat transfer in these tubes is mainly through the
radiation from the heating flame and incandescent refractory. The shock or shield tubes
are located at the entrance to the convection section and they receive more heat flux.
Convection tubes are on top of the heater, heated by the out going flue gas from the
radiant section.
Boilers: Fired boilers are boilers in which fuel is burned in the combustion chamber
associated with the boiler. The heat of the combustion is absorbed by the boiler to heat
the water and convert it to steam. Boilers are mainly of two types, water tube and fire
tube boilers, where water is in the tube is called water tube boiler and fire in the tube is
called the fire tube boiler.
Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, or molybdenum, which are added to
enhance mechanical or physical properties and/or corrosion resistance.
Fabrication: The preparation of piping and small connection for assembly, including
cutting, threading, grooving, forming, bending and joining of components into
subassemblies.
Face of the weld: The exposed surface of a weld on the side from which the welding
was done.
Filler material: The material to be added in making metallic or nonmetallic joints.
Fillet weld: A weld of approximately triangular cross section joining two surfaces
approximately at right angles to each other in a lap joint, tee joint, or corner joint.
Crack: A fracture type discontinuity characterized by a sharp tip and high ratio of
length to width to opening displacement.
Lack of fusion: A weld discontinuity in which fusion did not occur between weld
metal and base metal or adjoining weld beads.
Incomplete Penetration: The weld beads unable to fill the weld bevel groove.
Porosity: Cavity type discontinuities formed by gas entrapment during solidification of

the weld metal.
Rounded Indications: Indication’s with a maximum length of three times the width or
less on the radiograph.
Aligned Indications: A sequence of four (4) or more rounded indications should be

considered aligned.
Leg Length: is the thickness of a fillet weld, excluding any allowable reinforcement
measured through the leg.
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tm: Minimum thickness required (t) is equal to the design thickness as calculated by the
applicable ASME SEC VIII D1, ASME B31.3 (Barlow’s/Hoop’s) formula.
Hydrocarbon Services: Process streams of liquid or gaseous hydrocarbon (HC)

materials, or HC streams that may contain phenols, carbon dioxide, and ammonia.
Category "D" Fluid Service: A fluid service in which all the following apply:
1) The fluid handled is nonflammable, non toxic, and not damaging to human tissues
as defined in ASME B31.3 paragraph 300.2.
2) The design gage pressure does not exceed 150 psi (1030 kpa)
3) The design temperature is from -20°F (-29°C) through 366°F (180°C)
Category "M" Fluid Service: A fluid service in which the potential for personnel
exposure is judged to be significant and in which a single exposure to a very small
quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to
persons on breathing or bodily contact, even if prompt restorative measures are taken.
High Pressure Fluid Service: A fluid service for which the owner specifies the use of
high pressure piping.
Normal Fluid Service: A fluid service pertaining to most piping covered by the code
(ASME 31.3), that is, not subjected to the rules for Category D, Category M, or High
Pressure Service.
Low-Chrome Alloy Steels: Alloy materials with nominal chromium contents of 1% to

12% chrome.
Repair: The work necessary to restore the condition of the equipment suitable for safe
operation at the design conditions, without any deviation from the original configuration.
Abbreviations:
ADIP Amino-Di-IsoPropanol
DEA Di Ethanol Amine
DGA Di Glycol Amine
HAZ Heat Affected Zone
HC Hydrocarbon
MEA Mono Ethanol Amine
MSAER Mandatory SA Engineering Requirements
MT Magnetic Particle Testing
NDT Non Destructive Testing
Page 6 of 90
P&ID Piping and Instrumentation Drawings

PFD Process Flow Diagram
PMI Positive Material Identification
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiography Testing
RTFI Radiographic Film Interpretation
TEG Tri Ethylene Glycol
UT Ultrasonic Testing
VT Visual Testing
PV Pressure Vessel
TIP Tipical Inspection Plan
6 Inspection Guidelines
These guidelines are intended for inspectors and inspection engineers. Generally, the
steps for static process equipment inspection are shown in the Flowchart in attachment-A.
Equipment shall be inspected per Tipical Inspection Plan (TIP) and Checklist shown in
attachment B and DI-DXI respectively.
6.1 Vessels
6.1.1 Check the vessel drawing, construction code, material of construction,

internal parts, PWHT and dimensions (diameter, height and thickness)
6.1.2 Read the vessel file and note history of corrosion, repairs or
replacement if any.
6.1.3 Carry out joint inspection for vessel entry permit (confirm if
ventilation, blinds, scaffolds and lighting are provided) to ensure the
vessel is safe and adequately ventilated for vessel entry and obtain
vessel entry permit. At the time of entry arrange a man watch at the
man way of the vessel for your safety.
6.1.4 Primarily carry out external inspection for external leaks, external
damage, insulation or paint damage and external corrosion.
6.1.5 Gas tests the vessel internally before entry to the vessel for internal
inspection. Check the vessel has adequate venting and free from any
foul smell/toxic gas release while scales or deposit are disturbed.
Page 7 of 90
Check for adequate lighting and scaffold as required for inspection.

Also, at the time of vessel entry ensure a man stand by is available, for
your safety and company loss prevention.
6.1.6 Start preliminary internal inspection at all man ways (man way
inspection) going from bottom (If a column or tower) to the top or vise
versa. Record the observations at each level on a note pad. Start
entering the vessel from the top man way and assess the conditions of
nozzles, vessel head, vessel wall, vessel internal hardware’s (Trays,
bubble caps seal pan, support rings, demister pad, Glitch, etc.).
Identify each item and note the observations for your evaluation.
Request demister pad, packing removal and cleaning including packing
beds if required for detailed inspection. Focus on flash zones, inlet
areas, vapor phases, welds, etc.
6.1.7 While performing detailed inspection look for pitting corrosion,

erosion/corrosion, channeling, weld erosion/corrosion and cracks,
mechanical damages while opening and fixing, environmental
cracking, bulging and blistering and the like are some to look for with
in the vessel. A good cleaning and careful evaluation will help make a
good decision. If Fitness for Service (FFS) assessment is required, a
full evaluation will have to be done from design, operation, and history
of operation to assess the possibility of extending the service life of the
vessel.
6.1.8 After completion of the full inspection, request any additional cleaning
or removal of internals for detailed inspection or repairs if any, repair
procedure shall be issued by API certified or experienced senior
inspector in consultation with PV engineer. Reference the applicable
standards and codes in your recommendation.
6.1.9 Follow up the recommendations and the related repairs per Saudi
Aramco standards, the codes, ASME and API.
6.1.10 Carry out the final inspection on completion of the repairs and cleaning
as applicable. Assess the vessel condition for operation until the next
T&I date. If FFS assessment is done and the vessel can go through
minimally the EIS period, then request for change of EIS schedule.
Request a new vessel on hand for replacement.
6.1.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325,

SAES-D-008, SAES-W-010, SAES-W-015, ASME SEC VIII D1 and
API STD 510. Any repair to the main vessel will be hydrostatically
tested per SAES-A-004 and SAES-D-008. Test procedure shall be
provided by operation engineer of the unit or waivers shall be per
Page 8 of 90
SAEP-20 in advance. The test or waiver documents shall be filed for

reference.
6.2 Reactor Vessels
6.2.1 Check the reactor vessel drawing, construction code, material of

construction, internal Lining, attachment parts, PWHT and dimensions
(diameter, height and thickness).
6.2.2 Refer to the vessel file and read the history, if any cracking (welds,
vessel wall or lining), corrosion, disbonding of clad, Ring joint gasket
and grooves, repairs or replacement if any.
6.2.3 On dumping the catalyst carry out joint inspection (confirm ventilation,
blinds, scaffolds and lighting are provided) to ensure the vessel is safe
for entry and then obtain vessel entry permit. Arrange a man watch at
the man way of the vessel at the time of entry to the vessel for your
safety. Do not enter the vessel if the temperature is above 90ºF
approximately.
6.2.4 Primarily carry out external inspection of the vessel for signs of
external leaks, external damage, insulation damage, external corrosion
and cracks in external attachment welds which can be detected by MT
and sized by UT, (common occurrence).
6.2.6 Start preliminary inspection at manway (manway inspection) going

from top to the bottom dished head internally. Record the observations
on a note pad at each level. Start entering the vessel from the top
manway and assess the conditions of nozzles, vessel head, vessel wall,
vessel internal lining and hardware’s (Trays, Valve caps, support rings,
Liners, etc.). Identify each item and note the observations for your
evaluation. Request catalyst screen to be removed if required for
detailed inspection. Focus on inlet/outlet areas, vapor phases, welds,
clad, attachments and WFMPT test all welds or minimum 10% of the
welds externally, PT test clad welds internal and all ring joint flanges
for crack initiation.
6.2.7 While making a detailed inspection, look for pitting corrosion,

Page 9 of 90

cracking, bulging and blistering and the like are some that will be
noted with in the vessel. A good cleaning for careful evaluation of the
defect will help to make a good decision.
If Fitness for Service (FFS) assessment is required, a full evaluation

will have to be done from design, operation, and history of operation to
assess the possibility of extending the service life of the vessel. This
can be done sizing the defects by UT and assessing the results.
All the ring joints must be PT checked for cracks including the ring
gasket. Cracks on them are very common due to the corners of the ring
groove which are considers high stress raising points.
as applicable. Assess the reactor vessel condition for operation until
the next T&I date. If FFS assessment is done and the vessel can go
through minimally the EIS period, then request for change of EIS
schedule. Request a new vessel on hand for replacement. This is not
applicable to rector vessels, unless the reactor vessel experienced
extreme temperature runaway causing severe metallurgical damage.

SAES-W-010, SAES-W-015, SAES-D-008, SAES-A-004, ASME SEC
VIII D1, and API STD 510. Any repair to the main vessel will be
hydrostatically tested. Test procedure shall be provided by operation
engineer of the unit or waivers shall be submitted per SAEP-20 in
advance. The test or waiver documents shall be filed for reference.
6.3 Platformer Reactor Vessel
6.3.1 Check the reactor vessel drawing, construction code, internal parts,
material of construction, PWHT and dimensions (diameter, height and
thickness).
6.3.2 Refer to the vessel file, read file and note history of corrosion,
replacement of internal parts, and repairs or replacement if any.
Page 10 of 90
6.3.3 On dumping the catalyst carry out joint inspection (confirm ventilation,
blinds, scaffolds and lighting are provided) to ensure the vessel is safe
for entry and then obtain vessel entry permit. Arrange a man watch at
the man way of the vessel at the time of entry to the vessel for your
safety. Do not enter the vessel if the temperature is above 90ºF
approximately.
damage, insulation damage, external corrosion and cracks in external
attachment welds which can be detected by MT and sized by UT,
(common occurrence).
foul smell/toxic gases are released while scales or deposit are
disturbed. Check for adequate lighting and scaffold as required for
inspection. Also, at the time of vessel entry ensure a man stand by is
available, for your safety and company loss prevention.
6.3.6 Start preliminary inspection at manway (manway inspection) at the top

dished head internally; ensure proper ladder is fixed to go down the
vessel. Record the observations on a note pad at each level. Start
entering the vessel from the top man way and assess the conditions of
nozzles, vessel head, vessel wall, vessel internal such as the deflectors,
scallops, scallops keeper bar gap, scallop position, seats & seat tack
welds, heat damage and perforation to scallops and center pipe, dents,
seat rings and other hardware’s. Identify each item and note the
observations for your evaluation. Request scallops and center pipe
removal for detailed inspection if required. Focus on inlet/outlet areas,
vapor phases, welds, clad, attachments and WFMPT test all welds or
minimum 10% of the welds internally and externally for crack
initiation.
6.3.7 While performing detailed inspection, look for pitting corrosion,

erosion/corrosion, channeling, weld erosion/corrosion & cracks,
noted with in the vessel. A good cleaning and careful evaluation will
help make a good decision.
If Fitness for Service (FFS) assessment is required, a full evaluation

assess the possibility of extending the service life of the vessel. This
can be done sizing the defects by UT and assessing the results.
Page 11 of 90
If deep channeling or pits are noted, do not attempt weld build up but
patch the location.
as applicable. Assess the reactor vessel condition for operation until
the next EIS period. If FFS assessment is done and the vessel can go
through minimally the T&I date, then request for change of EIS
schedule. Request a new vessel on hand for replacement. This is not
applicable to rector vessels, unless the reactor vessel experienced
extreme temperature runaway causing severe metallurgical damage.

SAES-W-010, SAES-W-015, SAES-A-004, SAES-D-008, ASME SEC
VIII D1, and API STD 510. Any repair to the main vessel will be
hydrostatically tested. Test procedure shall be provided by operation
6.4 Heat Exchangers
6.4.1 Check the Exchanger drawing, construction codes, material of shell,

tubes, tube sheet, baffles, heads, and dimensions (diameter, length and
thickness).
6.4.2 Read the Exchanger file and note history of corrosion, tube failures, re-
tubing frequency, other repairs, replacement and outstanding
recommendations if any.
6.4.3 Carry out joint inspection (check includes ventilation, blinds, scaffolds
and lighting) to ensure the exchanger shell is safe for entry. Obtain
exchanger work permit (including shell entry). At the time of shell
entry keep a man watch out side the shell for your safety.
damage, insulation or paint damage, external corrosion to the shell.
6.4.5 Gas tests the exchanger internally before entry to the exchanger for
internal inspection. Check the exchanger has adequate venting and
Page 12 of 90
free from any foul smell/toxic gas release while scales or deposit are
6.4.6 Start preliminary inspection after removal of the channel head cover
and floating head cover. Note the fouling condition. Do the same
when the tube bundle is pulled out. Inspect the extent of fouling.
Collect samples of fouling both from the shell and tube side for
laboratory analysis. Request adequate cleaning of the shell, heads,
covers and the tube bundle for full inspection.
6.4.7 Inspect the exchanger if adequately cleaned for inspection. If cleaning

is not adequate to perform inspection, request for further cleaning.
After adequate cleaning for inspection inspect as follows:
6.4.7.1 Check gasket faces of all parts (shell, heads, covers and tube
sheets).
6.4.7.2 Inspect the channel, floating heads and covers for coating and
anode failure if any, corrosion/erosion, any mechanical
damage. Check the thickness to ensure no signs of uniform
corrosion.
6.4.7.3 Inspect the shell for corrosion/erosion of shell and seam

welds, any mechanical damage. Check the thickness to
ensure no signs of uniform corrosion.
6.4.7.4 Check all nozzle condition to ensure they are free of

corrosion/erosion and check the thickness is with in the
allowable condition.
6.4.8 Tube bundle has to be thoroughly inspected as follows:
6.4.8.1 Inspect the tube sheets for corrosion/erosion, tube end

thinning (assess severity of Grooving at tube to tube sheet
contact. PT tests if tube to tube sheet seal welded, for
cracks or deep pits).
6.4.8.2 Go along the tube external surface, note for corrosion

thinning of tubes and impingement plates, pitting corrosion,
dents and the like. Take OD and ID measurement and
compare to the original for discrepancy. Check for enlarged
baffle holes and grooving to tubes. Take thickness measure
of the baffles to evaluate corrosion thinning. See if scales
remains between tube rows and if severe request re-cleaning.
Page 13 of 90
6.4.8.3 Inspect tube ID for un-removed scales. Check for pits with in
the tubes and measure the depth and compare it to the original
thickness. Measure tube end thickness and compare to the
original thickness. Use a boroscope, eddy current or MFL as
applicable to ensure the condition for further service.
6.4.9 While performing detailed inspection of the shell, look for pitting
corrosion, erosion/corrosion, channeling, weld erosion/corrosion &
cracks, mechanical damages while opening and fixing, environmental
cracking, bulging and blistering and the like are some damages that
will be noted with in the shell wall. A good cleaning and careful
evaluation will help make a good decision.
6.4.10 If Fitness for Service (FFS) assessment is required, a full evaluation

assess the possibility of extending the service life of the shell. This can
be done sizing the defects by UT and assessing the results.
6.4.11 After completion of the full inspection, request any other needs for
cleaning, repair or re-tubing, renewal of anodes if any as required.
Aramco standards SAEP-317, the codes, TEMA, ASME and
API STD 660.
6.4.13 Carry out the final inspection on completion of the repairs if any and
cleaning as applicable. Assess the exchanger condition for operation
until the next EIS period. If FFS assessment is done and the exchanger
can go through minimally the T&I date, then request for change of EIS
schedule. Request a new exchanger on hand for replacement or tube
bundle as applicable.
6.4.14 On completion of inspection and repairs if any, hydrostatically test the

exchanger both from the shell and tube side at its test pressure (Design
pressure x 1.5 for exchangers built before 1999 and design x 1.3 after
1999.). Note: The reactor effluent and some exchangers with
bellow design will require to be tested at differential test pressure
only. Refer to the name plate for the test pressure in addition to the
SIS for the test pressure. Tube leaks at hydrostatic test should be
plugged and retested. 10% tube plugging is allowed per operating
requirements (Usually Plug seal weld is not required if plugs are driven
tight confirmed by hydrostatic test. However, dissimilar metal are
used, then yes and at high temperature service as a precaution) may be
required if different material. Minimum of two tests to be done
followed by hot bolting depending on service condition, equipment
gasket faces, new gaskets and workmanship for floating head type
Page 14 of 90
exchangers, otherwise, three tests shall be required per SAEP-317, at

the discretion of the inspection engineer.
6.4.15 Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010,

ASME SEC VIII D1, API STD 660, TEMA and API STD 510. Any
repair to the main exchanger or otherwise, will be hydrostatically
tested. Test procedure shall be provided by operation engineer of the
unit or waivers shall be submitted per SAEP-20 in advance. The test
or waiver documents shall be filed for reference.
6.5 Reactor Effluent Heat Exchangers
6.5.1 Check the Exchanger drawing, construction codes, material of shell,

tubes, tube sheet, baffles, heads, lining material and dimensions
(diameter, length and thickness).
6.5.2 Read the Exchanger file and note history of corrosion, tube failures, re-
tubing frequency, lining failures, and other repairs or replacement if
any.
and lighting) to ensure the exchanger shell is safe for entry. Obtain
exchanger work permit (including shell entry). At the time of shell
entry keep a man watch out side the shell for your safety.
damage, insulation or paint damage, external corrosion to the shell
nozzles and the heads.
6.5.5 Gas tests the exchanger internally before entry to the exchanger for
internal inspection. Check the exchanger has adequate venting and
free from any foul smell/toxic gas release while scales or deposit are
6.5.6 Start preliminary inspection after removal of the channel head cover
and floating head cover. Note the fouling condition. Do the same
when the tube bundle is pulled out. Inspect extend of fouling and
collect fouling samples both from the shell and tube side for laboratory
analysis. Request adequate cleaning of the shell, heads, covers and the
tube bundle for full inspection.
6.5.7 Inspect the exchanger if adequately cleaned for inspection. If cleaning

is not adequate to perform inspection, request for further cleaning.
After adequate cleaning for inspection:
Page 15 of 90
6.5.7.1 Check gasket faces of all parts (shell, nozzles, heads, covers
& tube sheets).
6.5.7.2 Inspect the channel heads and covers for corrosion/erosion,

any mechanical damage. Check the thickness to ensure no
signs of uniform or localized corrosion exists.
6.5.7.3 Inspect the shell for corrosion/erosion at seam welds, shell

plate and any mechanical damage. Check the thickness to
ensure no signs of uniform or localized corrosion exists.
Carry out PT test at random locations for cracks on shell clad
or lining (if any), and all ring joints.

allowable condition and gasket faces free from damages.
6.5.8 Tube bundle has to be thoroughly inspected as follows:
6.5.8.1 Inspect the tube sheets for corrosion/erosion, tube end

thinning (assess severity of grooving at tube to tube sheet
contact. PT tests if tube to tube sheet, seal welded for
cracks or deep pits).
6.5.8.2 Go along the tube external surface, note for corrosion

thinning of tubes & impingement plates, baffle plates & tie
rods, pitting corrosion, dents and the like. Take OD and ID
measurement and compare to the original for discrepancy.
Check for enlarged baffle holes and grooving to tubes. Take
thickness measure of the baffles to evaluate corrosion
thinning. See if scales remains between tube rows and if
severe request re-cleaning.
6.5.8.3 Inspect the tube ID for un-removed scales. Check for pits
with in the tubes and measure the depth and compare it to the
original thickness. Measure tube end thickness and compare
to the original thickness. Use boroscope, eddy current or
MFL as applicable to ensure the condition of the tubes for
further service.
6.5.9 While performing detailed inspection of the shell, look for pitting
corrosion, erosion/corrosion, channeling, weld erosion/corrosion and
cracks, mechanical damages while opening and fixing, environmental
cracking, bulging and blistering and the like are some damages that
will be noted with in the shell wall. A good cleaning and careful
evaluation will help make a good decision.
Page 16 of 90
6.5.10 If Fitness for Service (FFS) assessment is required, a full evaluation

assess the possibility of extending the service life of the shell. This can
be done sizing the defects by UT and assessing the results.
cleaning, repair or re-tubing, renewal of tubes or tube bundle.
Aramco standards, the codes, TEMA, ASME and API STD 660.
6.5.13 Carry out the final inspection on completion of the repairs if any and
cleaning as applicable. Assess the exchanger condition for operation
until the next EIS period. If FFS assessment is done and the exchanger
can go through the T&I date, then request for change of EIS schedule.
Request a new exchanger on hand for replacement or tube bundle as
applicable.
6.5.14 On completion of inspection and repairs if any, the exchanger will be

tested both from the shell and tube side at its test pressure (Design
differential pressure x 1.5 for equipment built before 1999 and 1.3 x
for equipment after 1999). Note: The reactor effluent and some
exchangers with bellow design will require to be tested at
differential test pressure only. Refer to the name plate for the test
pressure in addition to the SIS for the test pressure. Tube leaks at
hydrostatic test pressure should be plugged and retested. 10% tube
plugging is allowed per codes.
6.5.15 Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010,

ASME SEC VIII D1, API STD 660, TEMA and API STD 510. Any
repair to the main exchanger or otherwise, will be hydrostatically
tested. Test procedure shall be provided by operation engineer of the
unit or waivers shall be submitted per SAEP-20 in advance. The test
or waiver documents shall be filed for reference.
6.6 Fin Fan Cooler
6.6.1 Check the Fin-Fan cooler’s drawing, construction code, material of

heads and tubes, material and dimension (diameter, length and
thickness).
6.6.2 Read the Fin-Fan cooler file and note history of corrosion, tube
failures, re-tubing frequency, failures if any and other replacement or
repairs if any.
Page 17 of 90
6.6.3 Carry out joint inspection (check includes blinds, scaffolds and
lighting) and obtain work permit to ensure the Fin-Fan cooler’s is safe
to inspect. At the time of inspection keep an assistant with you for
your safety.
damage to shroud, fans, and structure’s, Tube fins and or paint damage,
external corrosion to the header and nozzles.
6.6.5 Before tube internal inspection, the fin fan header should be visually
seen inside through the plug holes and gas test to ensure the headers
are free from toxic gas release. While inspecting have an assistant with
you for your safety and company loss prevention.
6.6.6 Start preliminary inspection after removal of all header plugs from
both headers or removal of 10% plugs as applicable. Note the fouling
condition. Do the same when the tubes and headers are cleaned.
Inspect extent of fouling and collect samples from both header and
tubes for laboratory analysis. Request maintenance to clean adequately
the headers and tubes for boroscope, MFL and eddy current inspection
as applicable.
6.6.7 Inspect the Fin Fan whether adequately cleaned for inspection. If
cleaning is not adequate to carry out inspection, request for further
cleaning. After cleaning for inspection:
6.6.7.1 Check gasket faces of all plugs and bolts. Check the bolt and
header treads for any significant damage.
6.6.7.2 Inspect the headers for corrosion/erosion, tube end thinning

and any mechanical damage. Check the thickness to ensure
no signs of uniform or localized corrosion exists on the
header and nozzles.

allowable condition.
6.6.7.4 Tube bundle has to be thoroughly inspected as follows:
6.6.7.4.1 Inspect the tube sheets for corrosion/erosion, tube

end thinning and severity of grooving, at tube to
tube sheet contacts.
6.6.7.4.2 Go along the tube external, note corrosion

thinning of tubes and fin damage. Check if the
bolting arrangement of the cooler is adequate.
Page 18 of 90
Look if scales remain between tube rows and if

severe, request re-cleaning.
6.6.7.4.3 Inspect the tube ID for un-removed scales. Check

for pits with in the tubes and measure the depth
and compare it to the original thickness if
possible. Measure tube end thickness and
compare to the original thickness if possible. Use
a boroscope to reach inaccessible locations of the
tubes to ensure the condition of the tubes or
arrange to carry out eddy current testing as
applicable. If tubes indicate a range more than
60%, carry out 100% and plug those above 60%
for safe operation.
cleaning, repair or re-tubing if any as required.
Aramco standards, the codes, ASME and API STD 661.
as applicable. Assess the cooler condition for operation until the next
T&I period. If Fin Fan inspection reveals that the equipment do not
comply with the inspection finding for further service, then FFS
assessment has to be done and the Fin Fan can go through minimally
the EIS period, then request for change of EIS schedule. Request a
new cooler on hand for replacement.
6.6.11. After the completion of inspection and repairs if any, the exchanger
will be tested from the tube side at its test pressure (Design pressure x
1.5 for equipment prior to 1999 and 1.3 x design for equipment built
after 1999). Refer to the name plate for the test pressure in addition to
the SIS for the test pressure. Tube leaks at hydrostatic test should be
plugged and retested. 10% tube plugging is allowed per codes. It is
required to observe leaks from both the header plugs and tube rolls at
the back of the headers.
6.6.12 Applicable standards and codes: SAEP-20, SAES-A-004, SAES-W-

010, ASME SEC VIII D1, API 661 and API STD 510. Any repair to
the main cooler will be hydrostatically tested. Test procedure shall be
provided by operation engineer of the unit or waivers shall be
submitted per SAEP-20 in advance. The test or waiver documents
shall be filed for reference.
Page 19 of 90
6.7 Process Heaters
6.7.1 Check the heater drawing, construction code, material of radiant &
convection tubes, tube support & tube guide, refractory, Skin
Thermocouple and or Thermo well, Damper and Baffle plates and
dimensions of individual items (diameter, length/height and thickness)
as applicable to the heater type (Cylindrical or horizontal). Check the
burner assembly and orientation of burner tip and material.
6.7.2 Read the heater file and note history of corrosion, tube failures, history
of over heating, failures and re-tubing frequency, if any and other
replacement or repairs.
6.7.3 Carry out joint inspection (verify if, blinds and ventilation, lighting,
scaffolding provided) and obtain entry permit to ensure the heater is
safe to enter and inspect. At the time of inspection keep a man watch
for your safety.
6.7.4 Primarily carry out external inspection for external flue gas leaks,
external damage to heater casing, and structure’s, Burner blocks and
fuel leaks. It is suggested an infrared survey is done prior to shutdown
of the heater to identify hotspots and hot tubes and any refractory
damage to heater casing.
6.7.5 Gas tests the heater internally before entry to the heater for internal
inspection. Check the heater has adequate venting and free from any
6.7.6 Start preliminary visual inspection of the heater internally, pay

attention to the heater floor, burner assembly, burners and snuffing
steam connections, the refractory walls, bottom, mid and top tube
guides and the seat as applicable and accessible.
Inspect tubes, elbows/U-bends, and skin thermocouples for significant

over heating, bulging, bowing /distortion and scaling of tubes and
recommend cleaning for detailed inspection.
6.7.7 Evaluate if the heater tubes are adequately cleaned for inspection. If
cleaning. Inspection after adequate cleaning:
6.7.7.1 Check tube surfaces externally for any significant corrosion,

mechanical damage, bulge, tube distortion or bowing.
Page 20 of 90
6.7.7.2 Request for UT check on full length of tubes including

elbows at top and bottom, random hardness at the most over
heated area/flame impinged area. RT the inlet and outlet
tubes including U bends (for metal loss, coking, cracking
etc.). Also, concentrate on the shock and hip tubes if any.
Compare and Evaluate results well in advance to predict
problem areas.
6.7.7.3 Get Thermo-wells removed and skin thermocouple cleaned

for visual and DP test and evaluates results. Request
Thermowell continuity test for acceptance.
6.7.7.4 Check snuffing steam nozzles/connection for plugging and

corrosion.
6.7.7.5 Check the floor bricks or refractory and wall refractory for
any significant damage and request repairs as applicable.
6.7.7.6 Inspect the bottom U-bend and attachment tube guide for
corrosion damage externally.
6.7.7.7 Inspect closely the interim tube guides, top tube guides and
tube supports for damaged bolts, erosion/corrosion and
damage to tube contact.
cleaning, repair or re-tubing if any. Hydrostatic test will be required
if major repairs are executed for acceptance.
as applicable. Assess the heater condition for operation during the next
EIS period. If heater inspection reveals the heater do not comply with
the inspection finding for further service, then FFS assessment has to
be done and the heater can go through minimally the EIS period, then
request for change of EIS schedule. Request a partial or full re-tubing
of the heater next time with spare tubes on hand for replacement.
6.7.11 On completion of inspection and repairs if any, the heater will be tested
from the tube side at its test pressure (Design pressure x 1.5 for heater
built before 1999 and 1.3 x design for those built after 1999) only if
repairs are performed. Refer to the name plate for the test pressure in
addition to the SIS for the test pressure. Tube leaks at hydrostatic test
should be renewed partially or in full as deemed and retested.
Page 21 of 90
6.7.12 Applicable standards and codes: SAEP-20, SAES-W-010, SAES-A-

004, ASME SEC VIII D1, API STD 530 and API STD 510. Any
repair to the heater will be hydrostatically tested per SAES-A-004 and
ASME SEC VIII D1. Test procedure shall be provided by operation
6.8 Reformer Heater
6.8.1 Check the heater drawing, material of radiant and convection tubes,
tube support/tube guide, refractory, Thermo well, Damper plates and
dimensions of individual items (diameter, length and thickness) as
applicable to the heater (horizontal). Check the burner assembly and
orientation of burner tip and material.
6.8.2 Read the heater file and note history of corrosion, tube failures, history
of over heating, failures and re-tubing frequency, if any and other
replacement or repairs.
for your safety.
6.8.4 Primarily carry out external inspection for external flue gas leaks,
external damage to heater casing, and structure’s, Burner blocks and
fuel leaks. It is suggested an infrared survey is done prior to shutdown
of the heater to identify hotspots and hot tubes and any refractory
damage to heater casing.
6.8.5 Gas tests the heater internally before entry to the heater for internal
inspection. Check the heater has adequate venting and free from any
6.8.6 Start preliminary visual inspection of the heater internally, pay

attention to the heater floor, burner assembly, burners, snuffing steam
connections, and the refractory walls.
6.8.6.1 Number the tubes per cell starting from north to south or west
to east vice versa.
6.8.6.2 Inspect individual tube, for overheating, bulging, bowing,

surface discontinuities, such as micro fissuring, cracks and
Page 22 of 90
the like. Attention to be paid in locations opposite to the

burner or flame area.
6.8.6.3 Carry out creep measurement on all tubes; compare the

results with the previous creep measurement results.
Evaluate the creep behavior. Recommend all tubes with
creep above 3.5% for renewal. Arrange Magnetize, LOTIS or
H-scan to carry out creep measurement and evaluate the
results aided by computer, which will give the tube renewal
criteria based on creep and crack initiation in the tube. Crack
indication above 30% should be considered for renewal if not
sooner.
6.8.7 Evaluate if the heater tubes are adequately cleaned for inspection. If
cleaning is not adequate to carry out inspection, request for adequate
cleaning.
Inspection after adequate cleaning:
6.8.7.1 Check tube surfaces externally for any significant corrosion,

mechanical damage, bulge, tube distortion or bowing and
fissuring.
6.8.7.2 Get Thermo-wells removed and cleaned for visual and DP

test and evaluate results. Request Thermowell continuity test
for acceptance.
6.8.7.3 Check snuffing steam nozzles/connection for plugging and

corrosion.
6.8.7.4 Check the floor bricks, refractory and wall refractory for
bulge or any significant damage. Request repairs if required
as applicable.
6.8.7.5 Inspect the bottom transfer/pigtail pipe over heating and for
crack damage externally. Carry out PT test on all weld joints
for cracks.
6.8.7.6 Inspect the inlet pigtail pipe for crack damage at the weld
joints at inlet header and catalyst tube. Open the blind nozzle
flanges on the inlet header, check for fouling. If required get
it cleaned free of the foulant.
6.8.7.7 Inspect the steam generator, economizer and super heater

coils visually and by UT gauging.
6.8.7.8 Check the dampers and their operability.
Page 23 of 90
6.8.7.9 Inspect the stack where accessible for cleanliness and

refractory damage.
as applicable. Assess the heater condition for operation during the next
6.8.11 On completion of inspection and repairs if any, the heater will be tested
from the tube side at its test pressure (Design pressure x 1.5 for heaters
built before 1999 and 1.3 x after 1999). Refer to the name plate for the
test pressure in addition to the SIS for the test pressure. Tube leaks at
hydrostatic test should be renewed as deemed and retested.
Hydrostatic test in the case of this heater shall not be practical due
to the catalyst and the refractory. Therefore, the heater shall be
tested pneumatically with prior approval or leak tested with a
waiver in lieu of hydrostatic test.
6.8.12 Applicable standards and codes: SAEP-20, SAES-W-010, ASME SEC

VIII D1, API STD 530 and API STD 510. Any repair to the heater will
be hydrostatically tested per SAES-A-004 and ASME SEC.VIII D1 if
not a waiver shall be processed and leak test shall be performed at the
available plant nitrogen pressure. Test procedure shall be provided by
operation engineer of the unit or waivers shall be submitted per SAEP-
20 in advance. The test or waiver documents shall be filed for reference.
6.9 Industrial Boilers
6.9.1 Check the boiler drawing, material, size of tubes, fire bricks and
refractory, Steam drum internals, Baffle plates and dimensions of
individual items (diameter, length and thickness) as applicable to the
boiler. Check the burner assembly, orientation of burner tip and
material.
6.9.2 Read the boiler file and note history of corrosion, tube failures, history
of overheating, boiler failures and re-tubing frequency, and other forms
of repairs or replacement if any.
Page 24 of 90
for your safety.
6.9.4 Carry out preliminary external inspection for external flue gas leaks,
external damage to boiler casing, and structure’s, Burner assembly and
fuel leaks.
6.9.5 Gas tests the boiler internally before entry to the boiler for internal
inspection. Check the boiler has adequate venting and free from any
6.9.6 Start preliminary visual inspection of the boiler internally, (furnace or

fire box, bank and super heater section, flues gas duct, steam and mud
drums, economizer if available) pay attention to the boiler floor, bank
tubes, burner assembly, burners, the refractory to the walls and roof,
flue gas duct and stack.
6.9.7 Inspect tubes, bends, significant overheating of target wall tubes,

bulging, bowing /distortion and scaling of tubes. Recommend tube
external and internal cleaning for detail inspection.
6.9.8 Evaluate if the boiler tubes are adequately cleaned for inspection. If
cleaning. Inspection after adequate cleaning:
6.9.8.1 Check tube surfaces externally for any significant corrosion

or mechanical damage, bulge, tube distortion or bowing.
Concentrate on the target wall and roof tubes for possible
flame impingement and tube surface bulge.
6.9.8.2 Request UT for full length of tubes including bends, Hardness

at random locations most affected by flame. Compare and
Evaluate results well in advance to predict problem areas.
6.9.8.3 Inspect the steam drum and internals for cracks, corrosion and
other damages. Inspect all tubes internally using boroscope
to assess the tube ID condition. Evaluate if chemical cleaning
is to be performed. Also, mark a meter length tube for scale
measurement if tube ID’s are heavily scaled or every other
T&I.
Page 25 of 90
6.9.8.4 Inspect the mud drum for corrosion accumulated deposit.

Tube ends and tube end thinning and the like.
6.9.8.5 Inspect the flue gas duct, stack for accumulated ash, clean and
inspect for cracks and damage to the refractory that may
eventually result in flue gas leaks while in operation.
as applicable. Assess the boiler condition for operation during the next
6.9.12 On completion of inspection and repairs if any, the boiler shall be

pressure tested at its test pressure (Design pressure x 1.5). Refer to the
name plate for the test pressure in addition to the SIS for the test
pressure. Tube leaks at hydrostatic test should be renewed partially or
in full as deemed and retested.
6.9.13 Applicable standards and codes: SAEP-20, SAES-W-010, ASME SEC

VIII D1, API STD 530 and API STD 510. Any repair to the heater
will be hydrostatically tested per SAES-A-004 and ASME SEC VIII
D1. Test procedure shall be provided by operation engineer of the unit
or waivers shall be submitted per SAEP-20 in advance. The test or
waiver documents shall be filed for reference.
6.9.14 After the commissioning the boiler, the safety valves should be floated
prior to full operation. An in-place test procedure should be followed
strictly in performing the test.
6.10 Tanks
6.10.1 Check the tank drawing, construction codes, and material of

construction, internal parts, and dimensions (diameter, height and
thickness).
6.10.2 Read the tank file and note history of corrosion, repairs and
replacement if any.
Page 26 of 90
and lighting) and obtain entry permit to ensure the Tank is safe to enter
and inspect. At the time of inspection keep a man watch for your
safety.
damage, insulation or paint damage, external corrosion.
6.10.5 Ensure the tank is isolated with proper blinds. Obtain entry permit
from operation. Prior to internal inspection entry gas test to make sure
no toxic gases are released. While entry to the tank, have a man stand
by at the manway for your safety and company loss prevention.
6.10.6 Start preliminary inspection at all manways (manway inspection) going

from bottom (all around) to the top. Record the observations on a note
pad at each level. Start entering the tank from the bottom man way and
assess the conditions of nozzles, tank bottom plates, tank shell plates,
tank internal hardware’s (Columns, float, supports/legs, sumps, etc.).
Identify each item and note the observations for your inspection
evaluation.
6.10.7 While performing detail inspection look for pitting corrosion,

mechanical damages while opening and closing, environmental
noted with in the tanks. Coating conditions, if coated. A good
cleaning and careful evaluation will help make a good decision. Some
time Fitness for Service inspection (FFS) assessment will be required
and full evaluation will have to be done from design, operation, and
history of operation to increase the service life of the tank.
cleaning or removal and cleaning of internals for detail inspection and
repairs or renewal if any.
Carry out the final inspection on completion of the repairs and cleaning
as applicable. Assess the tank condition for operation during the next
EIS period. If FFS assessment is done and the tank can go through
minimally the EIS period, then request for change of EIS schedule.
Request replacement of the tank plates.

SAES-D-008, SAES-W-010, SAES-W-015, ASME SEC VIII D1, API
Page 27 of 90
STD 510, and API STD 653. Any repair to the tank will be
hydrostatically tested per SAES-A-004. Test procedure shall be
provided by operation engineer of the unit or waivers shall be
submitted per SAEP-20 in advance. The test or waiver documents
shall be filed for reference.
Revision Summary
26 November 2007 New Saudi Aramco Inspection Procedure.
Page 28 of 90
Attachment – A
FLOWCHART-PROCESS EQUIPMENT EXTERNAL AND INTERNAL INSPECTION PER
TYPICAL INSPECTION PLAN (TIP)
Page 29 of 90
Attachment – B I
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -

VESSELS
Inspection Phase Reference
1 Reference and Records: Review the following: Project Data Books.
• Operation Procedure
• SIS sheet information Equipment file
• EIS periods, revision and deviations
• Equipment as built drawing
• Design data
1. Material
2. Dimensions and Thickness
3. Pressure/Temperature
4. PWHT
• OSI drawings and TML points
2 Equipment File Information: Review the following: Equipment file

• Historical T&I’s information
• OSI information SAIF
• Corrosion information
• Repairs and frequency
• Recommendation
3 Work permit (WP) and personnel safety: GI-0002.1 & self

• Ensure your WP is valid.
• Make sure what process products in the equipment
• Have a joint inspection before accepting the permit
• Have your own assessment before entry
4 External inspection: Inspect the following: 00-SAIP-75

• Insulation and painting
• Foundation, skirts, fire proof and support bolts and nuts
• Nozzles including the manway
• Flange Leaks
• Any other leaks from the equipment
• Enter findings in Operation/Inspection Log Book
5 Internal inspection: Inspect the following: SAEP-20, SAEP-325, SAES-D-008, SAES-A-

• Fouling and cleanliness 004,
• Top Head and Nozzles including manway API STD 510, API STD 572. Checklist-DI, DII,
• Demister Pad DIII
• Trays, scallops, catalyst, packing, support and support rings
• Shell wall , clad, epoxy, in/out nozzles and manway
• Bottom head and nozzles
• Corrosion, Erosion, mechanical damage, etc., on internal
6 Worksheets and Tracking:
• Issue worksheets on major findings
• Follow up worksheet implementation and closure.
7 Final Inspection:
• Carry out final inspection on completion of maintenance
activities and issue box up report.
Page 30 of 90
Page 31 of 90
Attachment – B Ii
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT

HEAT EXCHANGERS
1 Reference and Records: Review the following:
• Operation Procedure Project Data Books.
• SIS sheet information
• EIS periods, revision and deviations Equipment file
• Design data
1. Material
4. PWHT
2 Equipment File Information: Review the following:
• Historical T&I’s information Equipment file
• OSI information
• Corrosion information SAIF
• Recommendation
3 Work permit (WP) and personnel safety:
• Ensure your WP is valid. GI-0002.1 & self
4 External inspection: Inspect the following:
• Insulation and painting 00-SAIP-75
• Flange or any other leaks from the equipment
5 Internal Inspection: Inspect the following:
• Fouling and cleanliness of heads, shell and tube bundle. SAES-A-004, SAEP-325, SAES-D-008, SAEP-317,
• Anodes and Epoxy if any. API STD 510, API STD 660, API RP 572, Checklist-
• Stationary Head welds, Pass Partician plates for weld damages DIV, DV, DX.
and corrosion
• Shell head and Floating Head welds for damages and corrosion
• Nozzles, flange gasket faces
• Shell, shell welds, nozzles and faces
• Tube bundle
• Tube sheets for damages and corrosion
• Tubes inside and outside for corrosion thinning
• Dimensional check of tubes, baffles
• Tie rods and fasteners
• Shell and Tube side hydro test
7 Final Inspection:
activities and issue box up report
Page 32 of 90
Attachment – B Iii
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT

AIR FIN COOLERS
1 Reference and Records: Review the following Project Data Books.

• Design data
1. Material
4. PWHT

• Recommendation


• Enter findings in the log book
5 Internal Inspection: Inspect the following: SAES-A-004, SAES-D-008, SAEP-317,

• Headers: Inspect header plugs, headers and plug sheets and API STD 510, API STD 661, API RP
gaskets 572,Checklist-DVI
• Tubes ID and OD for corrosion and damages
• Nozzles, vents and drains
• Tube fins, Shroud and hood, structure, fan assembly, ladders
and platform
• Hydro test
7 Final Inspection:
• Carry out final inspection on completion of
maintenance activities and issue box up report
Page 33 of 90
Attachment – B Iv
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -HEATERS

1 Reference and Records: Project Data Books.

Review the following:
• Operation Procedure Equipment file
• Design data
1. Material
4. PWHT
2 Equipment File Information: Equipment file

Review the following:
• Historical T&I’s information SAIF
• OSI information
• Recommendation
3 Work permit (WP) and personnel safety:

• Ensure your WP is valid. GI-0002.1 & self

5 Internal inspection: Inspect the following: SAES-A-004, SAES-D-008, SAEP-325,

• Heater casing and painting API STD 510, API STD 530, API STD 560,
• Burners and burner tips API RP 573, Checklist-DVII
• Heater floor and fire bricks/refractory
• Wall and roof refractory
• Radiant tubes
• Tube guides-bottom, mid and top
• Convection tubes and tube guides
• Repairs and hydro test
7 Final Inspection:
Page 34 of 90
Attachment – B V
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT - BOILERS

1 Reference and Records: Review the following: Project Data Books.

• Design data
1. Material
4. PWHT

• Recommendation


5 Internal inspection: Inspect the following: SAES-A-004, SAES-D-008, SAEP-325,

• External inspection of casing, foundations and stacks. API STD 510, API RP 573, Checklist-DIX
• Furnace, burners, floor bricks and refractory
• Furnace tubes, super heater tubes, bank tubes and economizer
tubes
• Inlet and outlet ducts
• Steam drum and internals
• Mud drum and internal
• UT, RT, MPI, boroscoping boiler tubes and drums
• Gauge glass, side glass, man ways
• Soot blower elements
• Stack and internal refractory
7 Final Inspection:
Page 35 of 90
Attachment – B Vi
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -TANKS
Reference and Records: Review the following:
1 • Operation Procedure Project Data Books.
• EIS periods, revision and deviations Equipment file
• Design data
1. Material
4. PWHT
Equipment File Information: Review the following:
2 • Historical T&I’s information Equipment file
• OSI information
• Corrosion information SAIF
• Recommendation
Work permit (WP) and personnel safety:
3 • Ensure your WP is valid. GI-0002.1 & self
External inspection: Inspect the following:
4 • Insulation and painting 00-SAIP-75
5 Internal Inspection: Inspect the following:
• Overview API STD 620, API STD 650, API STD 653, Checklist-
• Tank External XI, SAES-A-004
• Bottom Interior service
• Shell seams and Plates
• Roof Interior surface
• Fixed Roof Supports
• Fixed roof appurtenance
• Breathers and vents
• Emergency P/V Hatches
• Floating roof
• Floating roof pontoons
• Floating roof supports
• Primary shoe and toroidal assembly
• Rim mounted secondary’s
• Floating roof appurtenances
1. Roof manways,
2. Rim vents,
3. Vacuum breakers
4. Roof drains, open & closed,
5. autogauge systems & alarms
• Common Tank Appurtanaces
• Shell Nozzles
• Diffusers and rolling systems
• Swing lines
• Accesses structures
• Platform Frames
• Deck plates and gratings
• Rolling ladder
Page 36 of 90
Attachment – B Vi (Cont'd)
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -TANKS
7 Final Inspection:
Page 37 of 90
Attachment: C I – Inspection Checklist For Process Equipment-Vessel
Report No.: Date prepared:

Equipment No. & Service Location/ Area: Plant No.:
Reason for Inspection: Date Inspected
P&E Inspector: Field insp. Supervisor: Unit Supervisor :
Equipment data:
Shell Material Design Pressure, Kg/ cm²g or psig:
Shell thickness (mm or in) Design Temp. °C or °F:
Cladding/ Lining Corrosion Allowance (mm or in)
A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected
# ITEM A U NA NI COMMENTS
1.0 Top Head and Nozzles
Internal Corrosion (scales, pits, buildup)/Cracking
1.1
Describe location, appearance and depth.
1.2 Excessive scale presence. Describe
1.3 Weld condition/corrosion, perform WFMPT for cracks.
1.4 Condition of manway gasket surface
1.5 UT measurement- Top head & Nozzles including Manway
Internal and external cracks, erosion/corrosion, foreign
1.6
deposit
1.7 Insulation condition
Condition of attachment welds (Includes Lift lugs, pipe
1.8
supports etc.)
1.9 External and Internal coating/painting
2.0 Shell: Cylindrical and Conical

2.1
Describe location, appearance and depth
2.4 UT measurements-shell, cone section and heads
Inspect distributors (channel and pipe with holes) for
2.5
corrosion, erosion, fouling and blockage
Inspect the inlet outlet and draw off nozzles for corrosion,
2.6
erosion and thinning
2.7 Condition of Internal coating, External paint, Insulation
3.0 Demister Pad (DP)

3.1 Check if demister pad is not disturbed
Get DP removed and inspect vessel wall above and below
3.2
including the attachments
Inspect DP for fouling, damage and if compressed and
3.3
assess if can be reused for another cycle
Inspect DP fit up and attachment wires (size and material)
3.4
on completion of DP fit up
Packing, Packing Beds, Shell and

4.0
Distribut.
4.1 Check the packing and beds for loss and disturbances.
Check the packing and support beds and attachments for
4.2
corrosion, mechanical damage and looseness
Inspect the shell wall under the packing bed for corrosion,
4.3
grooving and pitting
Page 38 of 90

Equipment data:
Based on the finding (item 3.7) recommend complete
4.4
removal of packing for shell wall inspection
Attachment: C I – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT-VESSEL

(cont'd)

Equipment data:
5.0 Trays
5.1 Check both top and bottom of trays for fouling
5.2 Check the tray floor for bulge/ level and corrosion
Check the valves on trays for corrosion, looseness and
5.3
mechanical damage
Check the tray support ring condition and welds for
5.4
corrosion/erosion
5.5 Carry out dimensional check on trays and fittings.
6.0 Clad/Lining
6.1 Check if the lining clad or strip lining
6.2 Check if the vessel section or fully lined
6.3 Check the lining for disbanding and inspect all welds
6.4 Check for cracks or damage if lined with cement
6.5 Perform PT on welds
7.0 Bottom Head

7.1
7.4 Condition of man way gasket surface
UT measurement- Top head and Nozzles including
7.5
Manway
7.6
deposit
Page 39 of 90

Equipment data:
Condition of attachment welds (Includes Lift lugs, pipe
7.8
supports etc.)
Check the Vortex breaker for weld cracks, corrosion or
7.9
mechanical damage
7.10 Check internal and external coating/painting
8.0 Foundation/Supports
8.1 Condition of skirt and fire proofing
8.2 Condition of support bolts
8.3 Condition of foundation
NOTES:
Page 40 of 90
Attachment: C-Ii – Inspection Checklist For Process Equipment- Reactor Vessel

Equipment No. & Service: Location/ Area: Plant No.:
Reason for Inspection: Date Inspected:
P&E Inspector: Field Insp. Supervisor: Unit Supervisor:
Equipment data:
Material Design Press. Kg/ cm²: PSIG:
O
Size/ Thick. Mm/in Design Temp. °C: F:
Cladding / Lining Corrosion Allowance mm: In:
1.
Inlet Elbow
0
1.1 Check inlet elbow for scaling, Mechanical damage
Check both flanges, gasket faces and gasket for
1.2
damage
1.3 DP test the ring gasket and the flange groove for cracks
2.
Manway Nozzles and Top Head
0
Internal Erosion/Corrosion (scales, pits,
2.1 buildup)/Cracking
2.4 Condition of manway gasket and groove
2.5 UT measurement- Top head and Manway
2.6 Inspect the internal clad for bulge, cracks, disbonding etc
Check the condition of attachment and reinforcement
2.7 pad welds (Includes Lift lugs, pipe supports etc.) for
cracks
2.8 Check the condition of insulation
2.9 Check the inlet distributor for damages
3.
Shell and Internals:
0
Check the shell and top head clad for cracks, bulge
3.1
channeling, disbonding etc.
3.2 DP check the clad welds for cracks
Check distributor tray and support ring for any
3.3
abnormality
4.
Bottom Head
0
Check the outlet grid and screen and grid support beam,
4.1
attachment welds for any abnormalities
Inspect the bottom head, oulet nozzle and catalyst
4.2
dumping nozzle
4.3 PT check all welds including the clad
5. External
Page 41 of 90

Equipment data:
O
0
MPI and UT shear wave test all nozzle and attachment
5.1
welds for cracking
Test all vertical and circumferential seam welds by MPI
5.2
and UT shear wave Technique
Remove all Thermo wells and DP test Flanges, barrel for
5.3
cracks and continuity test
Attachment: C-II – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT- REACTOR VESSEL

(cont'd)


Equipment data:
O
Check all bolts used for closure are in good condition
5.4
(Sample one bolt for tensile test)
5.5 Check all gaskets are renewed in kind
5.6 Check the external insulation condition finally
6.
Foundation/Supports
0
6.1 Check condition of skirt and fire proofing
6.2 Check condition of foundation and support bolts
NOTES:
Page 42 of 90
Attachment: C-Iii – Inspection Checklist For Process Equipment - Platformer Reactor Vessel

Equipment data:
Size/ Thick. Mm/in Design Temp. °C: °F
Cladding / Lining Corrosion Allowance mm: in
1.0 Inlet Elbow
Check inlet elbow for excessive scaling, Mechanical
1.1
damage
1.2 Check both flanges and gasket faces
2.0 Top Head and Manway Nozzles

Internal Erosion/Corrosion (scales, pits,
2.1 buildup)/Cracking
2.3 Weld condition/corrosion
2.4 Condition of man way gasket face
2.5 UT measurement- Top head and Manway
Inspect the internal deflection plates, Scallop keeper
2.6 bars (for bending), breaking, missing or loose bolts and
weld defects
Check the condition of attachment and welds (Includes
2.7
Lift lugs, pipe supports etc.) for cracks
2.8 Check the condition of insulation
3.0 Internal, Scallops & Support Rings

Center pipe: Inspect for any damage caused( perforation
3.1
burnt or holed )
Scallops: Inspect individually all for mechanical, heat
3.2
damage and fouling or blocked ports
3.3 Check all support rings for twisting and cracking
Check the scallop support ring at the bottom of the

3.4
reactor for mechanical, weld and seat damage
4.0 Shell
Check the shell wall for corrosion, pits, channeling,
4.1
cracking, bulge and mechanical damage
4.2 UT measurements-shell and attachments
DP or WFMPI test the seam, nozzle and attachment
4.3
welds for cracks
5.0 Bottom Head

5.1 Inspect the bottom head for pitting gouging and cracking
Inspect the packing condition of the center pipe with the
5.2
bottom head for tightness
Page 43 of 90
Attachment: C-III – Inspection Checklist for Process Equipment - Platformer Reactor Vessel

Equipment data:
Size/ Thick. Mm/in Design Temp. °C: °F
Cladding / Lining Corrosion Allowance mm: in
5.3 UT measurement- Bottom head and Nozzles
6.0 Internal Assembly

6.1 Check all internals are assembled correctly.
Check clearance between internals are with in allowable
6.2
limits
Ensure the excess clearance are compensated by KAO
6.3
wool packing if required
7.0 External
MPI test all seam, nozzle and attachment welds for
7.1
cracking
7.2 Check the external insulation is in good condition
Check all bolts used for closure are in good condition

8.0
(Sample one bolt for tensile test)
9.0 Check all gaskets are renewed in kind
10.1 Check condition of skirt and fire proofing
10.2 Check condition of foundation and support bolts
NOTES:
Page 44 of 90
Attachment: C-Iv – Inspection Checklist For Process Equipment - Heat Exchanger


Equipment data:
DESCRIPTION Shell TUBES DESCRIPTION SHELL TUBES
Material Design Pressure Kg/cm²g/psig
Thick. mm/in Design Temperature °C / °F
Corrosion Allowance mm /in Hydro Test Pressure Kg/cm²g/psig
1.0 Channel Head, Cover and Nozzles
1.1
Weld condition/corrosion & condition of Pass partition
1.3
plate
1.4 Condition of gasket surfaces
1.5 UT measurement- Channel and Nozzles
1.6
deposit
1.8 Condition of attachment welds (Includes Lift lugs, etc.)
1.9 Channel cover
1.10 Check instrument connection for corrosion damage
1.11 Internal/External coating/painting
2.0 Shell: Cylindrical and Conical

2.1
Weld condition/corrosion (both longitudinal and
2.3
circumferential)
2.4 UT measurements-shell, cone and nozzles
Inspect lining and distributors if provided for corrosion,
2.5
erosion, fouling and blockage
Inspect the inlet, outlet nozzles for corrosion, erosion
2.6
and thinning
2.7 Inspect gasket faces
2.8 Condition of external paint, insulation
3.0 Demister Pad (DP)

3.1 Check if demister pad is not disturbed
Get DP removed and inspect shell wall above and
3.2
below including the attachments
Inspect DP for fouling, damage and if compressed and
3.3
assess if can be reused for another cycle
Inspect DP fit up and attachment wires (size and
3.4
material ) on completion of DP fit up
Page 45 of 90
Attachment: C-IV – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - HEAT EXCHANGER


Equipment data:
4.0 Tube Bundle
Check tube ID & OD fouling. Describe the extend of
4.1
fouling and locations
Measure ID and OD and compare to the original for
4.2
metal loss
Visually inspect ID and OD for pits measure the depth
4.3
of pit
4.4 Inspect tube ends for corrosion thinning.
If tube to tube-sheet welded, then perform DP test to
4.5
ensure no crack
Check the tube sheet for corrosion, erosion and any
4.6
mechanical damage
Notes:
Eddy current testing and evaluation of the tube

4.7
condition
Mark defective tubes for plugging or re-tubing as
4.8
required
Check baffle plates for corrosion, thinning and enlarged
4.9
tube holes
4.10 Check tie-rods for corrosion & damage
5.0 Floating Head Cover

5.1 Check for corrosion, erosion & pits
Check gasket face for corrosion, erosion, pit or
5.2
mechanical damage
Page 46 of 90
Attachment: C-IV – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - HEAT EXCHANGER


Equipment data:
6.0 Shell Cover
6.1 Check for corrosion, erosion & pits
Check gasket face for corrosion, erosion, pit or
6.2
mechanical damage
6.3 UT check
Check vent and drain for blockage and corrosion
6.4
thinning
7.1 Condition of support saddle and fire proofing
8.0 Hydrostatic Test

Test from shell side # Design x 1.5 (Built before1999
8.1
and 1.3 after 1999)
Test from Tube side # Design x 1.5 (Built before1999
8.2
and 1.3 after 1999)
Final Test from shell side # Design x 1.5 (Built
8.3
before1999 and 1.3 after 1999)
NOTES:
Page 47 of 90
Attachment: C-V – Inspection Checklist For Process Equipment

- Vertical Heat Exchanger

Equipment data:
DESCRIPTION Shell TUBE DESCRIPTION Shell Tube
Thick. mm/in Design Temperature Deg °C /°F
Corrosion Allowance mm/in Hydro Test Pressure Kg/cm²g/psig
1.0 Channel Head, Cover and Nozzles
1.1
1.4 Condition of gasket surfaces
1.5 UT measurement- Channel and Nozzles
1.6 Internal and external cracks, erosion/corrosion, foreign deposit
1.9 Channel cover
1.11 External coating/painting
2.0 Shell
2.1
2.3 Weld condition/corrosion (both longitudinal and circumferential)
2.4 UT measurements-shell, cone and nozzles
Inspect lining if provided. Check for corrosion/erosion, disbanding and
2.5
bulges
2.6 Inspect the inlet, outlet nozzles for corrosion, erosion and thinning
2.7 Inspect gasket faces
2.8 Condition of external paint, insulation
3.0 Bellow
3.1 Check if bellow is dimensionally not disturbed
3.2 PT check the bellow for cracks
Request and Witness the Pressure test of the bellow at 1.5 x design
3.3
differential pressure
4.0 Tube Bundle

Check tube ID and OD fouling. Describe the extend of fouling and
4.1
locations
4.2 Measure ID and OD and compare to the original for metal loss
4.3 Visually inspect ID and OD for pits, measure the depth of pit and record
Page 48 of 90

Equipment data:
4.4 Inspect tube ends for corrosion thinning/weld erosion/cracks.
Page 49 of 90
Attachment: C-V – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT

- VERTICAL HEAT EXCHANGER

Equipment data:
4.5 If tube to tube-sheet welded, then perform PT test to ensure no crack
4.6 Check the tube sheet for corrosion, erosion and any mechanical damage
4.7 Eddy current testing and evaluate tube condition
4.8 Mark defective tubes for plugging or re-tubing as required
4.9 Check baffle plates for corrosion, thinning and enlarged tube holes
4.10 Check tie-rods for corrosion and damage
Notes:
5.0 Floating Head (cone type)

5.1 Check for corrosion, erosion and pits
5.2 Check gasket face for corrosion, erosion, pit or mechanical damage
6.0 Shell Cover

6.1 Check for corrosion, erosion and pits
6.2 Check gasket face for corrosion, erosion, pit or mechanical damage
6.3 UT check
6.4 Check vent and drain for blockage and corrosion thinning
7.1 Condition of support saddle and fire proofing
Page 50 of 90
Attachment: C-V – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT

- VERTICAL HEAT EXCHANGER

Equipment data:
Hydro test shell and tube side at 1.5 x differential pressure-Test from
8.1
shell side # Design x 1.5 (Built before1999 and 1.3 after 1999)
8.2 Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999)
Final Test from shell side # Design x 1.5 (Built before1999 and 1.3 after
8.3
1999)
NOTES:
Page 51 of 90
Attachment: C-Vi – Inspection Checklist For Process Equipment - Fin Fan Cooler

Equipment data:
DESCRIPTION HEADERS TUBES DESCRIPTION
Material Design Press.: Kg/cm²g/psig
Shell Thick: mm/ in Design Temp.: oC/oF
Corrosion Allowance: mm/ in Corrosion allowance: mm/in
1.
Inlet Header and Nozzles
0
1.1
Describe location, appearance and depth if accessible.
1.3 Weld condition/corrosion and condition of Pass partition plate
1.4 Condition of all plug gasket surfaces and threads
1.5 UT measurement- Header box plates and Nozzles
1.6 Internal and external cracks, erosion/corrosion, deposit
1.8 Header plug seat/gasket face and threads
1.10 Check the vent and drain for plugging and corrosion
2.
Outlet Header and Nozzles
0
2.1
Describe location, appearance and depth if accessible.
2.3 condition of Pass partition plate and Weld/ corrosion
2.4 Condition of all plug gasket surfaces and threads
2.5 UT measurement- Header box plates and Nozzles
2.6 Internal and external cracks, erosion/corrosion, foreign deposit
2.8 Header plug seat/gasket face and threads
3.
Tubes
0
Visually see through the plug holes for tube end thinning and fouling at both
3.1
headers
3.2 Check tube leak marks behind the tube sheet
Page 52 of 90

Equipment data:
Get random RT taken on accessible tubes, around headers and at mid section
3.3
and evaluate corrosion
3.4 Check if tubes are sagged/bowed
3.5 Check condition of tube fins for damage or flattening
Page 53 of 90
Attachment: C-VI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - FIN FAN COOLER
Equipment data:
3.6 Inspect tube ends for thinning at both headers
3.7 Carry out MFL test to all or 10% of tubes and evaluate the results
3.8 Unacceptable tubes for plugging to be marked on site
3.9 Check the side frames for any possible damage
Check the condition of stiffeners, tube spacers, tube keepers and tube support
3.10
cross members
4.
Foundation/Supports
0
4.1 Condition of supporting columns/ beams and fire proofing
5.
General
0
5.1 Check the fan blades for cleanliness
5.2 Check the Plenum, fan ring, fan deck
5.3 Check the drive assembly for any abnormality
5.4 Check ladder and platforms if they are intact
NOTES:
Page 54 of 90
Attachment: C-VI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - FIN FAN COOLER
Equipment data:
DESCRIPTION HEADERS TUBES DESCRIPTION Details
2
Material Design Pressure Kg/cm , psig
Shell Thick: mm/ in Design Temperature Deg °C / °F
Corrosion Allowance: mm/ in Hydro Test Pressure in Kg/cm2 , psig
Notes:

6.1 Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999)
NOTES:
Page 55 of 90
Attachment: C-Vii – Inspection Checklist For Process Equipment - Heater

Equipment data:
Description Tubes Description
Tube Material Design Press.: Kg/cm²g/psig
Size/ Thick.: mm/in Design Temp.: oC/oF
Thickness: mm/in Corrosion allowance: mm/in
1.0 Tubes - Radiant
1.1 External scale
External corrosion-describe location appearance and
1.2
depth
1.3 Sagging/bulges/blisters
1.4 Tube OD measurement
1.5 Externally cleaned
1.6 Internally cleaned
1.7 UT measurement- Tubes and bends
1.8 Hardness measurement
1.9 Radiographic Inspection
1.10 Internal cracks, erosion/corrosion, foreign deposit
1.11 Tube supports and hardware
1.12 Weld condition
2.0 Tubes - Convection

2.1 External scales/debris
2.2 Tube fin condition
2.3 Tube supports and hardware’s
2.4 UT measurements, accessible locations
2.5 Tube distortion and bulges
3.0 Fittings
3.1 Corrosion-describe location appearance and depth
3.2 Distortion
3.3 Condition of tube rolls, plugs and threads
3.4 UT measurement
4.0 Casing and Internals

4.1 Insulation/Refractory
4.2 Insulation clips
4.3 Fire bricks
4.4 Inspection doors/ burner view port
4.5 Convection section
Page 56 of 90
Attachment: C-VII – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - HEATER


Equipment data:
4.6 Thermowells
4.7 Explosion door condition
4.8 Casing condition
4.9 Condition of external coating
4.10 Condition of access doors
5.0 Burner Assembly

5.1 Corrosion, deterioration of burner tips, coking
5.2 Condition of pilot burner
5.3 Thermocouple condition
5.4 Burner tiles condition
6.0 Heater Stack

6.1 External condition
6.2 Condition of support bolts and guy wire
6.3 Internal refractory
6.4 External insulation and coating
6.5 Condition of damper
6.6 Check if the damper blade is scaled or overheated
7.1 Condition of concrete support
7.2 Condition of steel support
7.3 Condition of fireproofing

8.1 Witness pressure test
8.2 Look for flange, and tube leaks.
NOTES:
Page 57 of 90
Attachment: C-Viii – Inspection Checklist For Process Equipment - Reformer Heater

Equipment data:
1.0 Tubes - Radiant
1.1 External scale
External corrosion-describe location appearance and
1.2
depth
1.3 Sagging/bulges/blisters
Tube OD measurement, Manual, eddy current or
1.4
Lotis, H Scan
1.5 Externally cleaned
1.6 Internally cleaned
1.7 UT measurement- Tubes and bends
1.8 Hardness measurement
1.9 Radiographic Inspection
Internal or external cracks, erosion/corrosion, foreign
1.10
deposit
1.11 Tube supports & hardware and lugs
Condition of Counter weight, connecting cable and
1.12
obstruction to movements
1.12 Tube weld condition
2.0 Tubes - Convection

2.1 External scales/debris
2.2 Tube fin condition
2.4 UT measurements, accessible locations
3.0 Fittings
3.1 Corrosion-describe location appearance and depth
3.2 Distortion
3.3 Condition of tube rolls, plugs and threads
3.4 UT measurement
4.0 Casing and Internals

4.1 Insulation/Refractory
4.2 Insulation clips
4.3 Fire bricks
Page 58 of 90
Attachment: C-VIII – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - REFORMER HEATER

Equipment data:
4.4 Inspection doors/ burner view port
Convection section
4.5 Condition of tubes, elbows/bends and refractory
4.6 Thermowells
4.7 Explosion door condition
4.8 Heater casing condition
5.0 Burner Assembly

6.0 Heater Stack

6.5 Condition of damper
7.1 Condition of support and fire proofing
7.3 Condition of fireproofing
8.0 Pneumatic or Hydrostatic test

8.2 Look for flange, roll and tube leaks.
NOTES:
Page 59 of 90
Attachment: C-Ix – Inspection Checklist For Process Equipment - Boiler

Reason for Inspection: T&I P&E Inspector: Date Inspected:
Equipment data:
Boiler Type:
Manufacturer: Design Pressure,
Model: Design Temperature,
Design Code Hydrotest pressure
Equipment Data:
Data: Steam Drum Water Drum Furnace tubes Super heater tubes Bank tubes Wall headers
Material
OD or ID
Thickness
1.0 Tubes, Drums-Waterside
Corrosion (scales, pits, buildup)/Cracking
1.1
1.3 Tubes free of blockage, scales
1.5 UT measurement- Drums
1.6 Condition of man way gasket surface
1.7 Tube boroscope inspection
1.8 Internal cracks, erosion/corrosion, foreign deposit
2.0 Tubes, Drums-Fireside

External tube corrosion, erosion, pitting (describe
2.1
location and size)
External drum corrosion, scales & deposits and
2.2
insulation loss.
2.4 UT measurements
2.6 External signs of roll leaks
2.7 Evidence of erosion from soot blowers
2.8 Condition of soot blowers
3.0 Headers
3.1 Internal scale and corrosion
3.2 Condition of hand hole plugs
3.3 External corrosion, erosion, deposits, scales
4.0 Water Column

4.1 Gage glass condition
4.2 Illuminators, reflectors, view glasses
Page 60 of 90
Attachment: C-IX – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - BOILER

Reason for Inspection: P&E Inspector: Date Inspected:
Equipment data:
Boiler Type:
Manufacturer: Design Pressure,
Model: Design Temperature,
Design Code Hydrotest pressure
Equipment Data:
Data: Steam Drum Water Drum Furnace tubes Super heater tubes Bank tubes Wall headers
Material
OD or ID
Thickness
4.3 Gage cocks and valves
4.4 Condition high and low water alarms
5.0 Casing
5.1 Condition of insulation/refractory
5.2 Condition of casing structures
5.3 Casing distorted, cracked, corroded or burnt
5.4 Any obstruction to thermal expansion
5.5 Condition all baffle tiles and caulking
5.7 Condition of external paint
6.0 Burner Assembly

8.0 Boiler Stack


Pressure tested # Design x 1.5 for boilers built before
9.2
1999 and Design x 1.3 after 1999
NOTES:
Page 61 of 90
Attachment: C-X – Inspection Checklist For Process Equipment - Unfired Boiler

Equipment data:
DESCRIPTION Shell Tube DESCRIPTION Shell Tube
Material Design Pressure Kg/psig
Thick.: mm/ in Design Temperature Deg °C/ °F
Corrosion Allowance :mm / in -- Hydro Test Pressure in Kg/psig
1.0 Tube-Waterside
Corrosion (scales, pits, buildup)/Cracking
1.1
1.3 UT measurement
1.4 Tube Distortion
1.5 Boroscope inspection
2.0 Tube/ Fireside

corrosion, erosion, pitting (describe location,
2.1
appearance and size)
2.2 Tubes blockage, scales, deposits
2.3 UT measurements
2.4 Tube boroscope inspection
2.5 Signs of tube roll leaks
2.6 Evidence of Tubesheet cracks
2.7 Refractory cracking and spalling
2.8 Ferrule conditions
3.0 Shell
3.1 Internal scale and corrosion
3.2 UT measurement
4.0 Gas Inlet/Outlet

4.1 Condition of insulation/refractory

NOTES:
Page 62 of 90
Attachment: C-Xi – Inspection Checklist For Process Equipment - Tank

Reason for Inspection: Date of Commissioning: Date Inspected:
Equipment data:
Shell Material Design Pressure, Kg/ psig:
Shell thickness: mm/in Max. Operating level meters /ft:
CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected Checklist Per API 653
# ITEM CA NC NI COMMENTS
1.0 Overview
1.1 Check the tank is cleaned, gas free and safe for entry
1.2 Check the tank is completely isolated from service.
Check the roof is adequately supported including
1.3
fixed roof structures and floating roof legs
Check for presence of falling objects hazards, such as
1.4
corroded roof items and appurtenance, etc.
1.5 Inspect slipping hazards on the tank floor and roof.
1.6 Check structural welds on the accessways and clips
Check surfaces required for inspection is free from
debris and oily surfaces where welding is to be
1.7
performed. Note areas requiring more cleaning or
sand blasting
2.0 Tank External

Inspect appurtenances opened during cleaning such
2.1 as lower floating swing sheave assemblies, nozzle
interior after removal of valves.
2.2 Hammer test or UT check the roof
2.3 Enter and inspect floating roof pontoon compartments
3.0 Bottom Interior Surface

Use flash light parallel to the bottom plates and
3.1 inspect the plates, welds and hammer test the entire
bottom.
Measure the depth of pitting and describe the
3.2
appearance ( sharp, lake like, dense scattered etc.
3.3 Mark areas for further inspection or patching
3.4 Mark areas for coupon sampling for inspection.
Inspect all welds for corrosion and leaks, particularly
3.5
the shell to bottom plate weld.
3.6 Inspect sketch plate for corrosion
Check the internal sump. If liquid found, recommend
3.7
for removal and inspect the welds and for corrosion.
3.8 Locate and mark voids under the bottom plates
Record bottom data on a lay out bottom drawing and
3.9
list the number of plates to renew or patches required
3.10 Vacuum test the bottom plate lap welds.
Inspect closely any discolored or wet areas by
3.11
hammer or UT scan.
3.12 Check all reinforcement pads, supports and clips
3.13 Inspect floating roof leg pads for pits, cuts etc
Inspect column bases of fixed roof support pads for
3.14
adequacy
3.15 Check the area beneath the swing line cable for
Page 63 of 90

Equipment data:
indication of cable cutting or damage
Page 64 of 90
Attachment: C-XI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT – TANK (cont'd)


Equipment data:
Identify and report low areas on the bottom that does
3.16
not drain adequately.
Inspect coating for discoloration, blisters, holes and
3.17
disbonding.
4.0 Shell Seams and Plates

Check the bottom 2” to 4” for corrosion /erosion due
4.1
to water accumulation.
Inspect and measure the depth of pits on each course
4.2
plate and measure the amount of metal loss.
4.3 Inspect shell to bottom plate weld
Inspect grooving damage from seal assembly
4.4
protrusion.
Inspect the existing coating for damage deterioration
4.5
and disbanding.
4.6 Check for seal rubbing
Visually check the shell plates for indication leaks and
4.7
leak marks
4.8 Survey the tank for roundness or bulges.
4.9 Check tank overflow nozzle internally & externally
5.0 Roof Interior Surface

5.1.
General
0
Visually inspect the under side surface of the tank
5.1.1 roof plates for scaling/deposit buildup, pitting, and
holes.
Hammer test or thickness gage for corrosion thinning
5.1.2 particularly in vapor space of floating roof and at the
edge of cone roof.
Check all clips, attachments to roof plates, welds for
5.1.3
cracks and damage.
5.1.4 Inspect the protective coating for any damage.
5.2 Fixed Roof Support
5.2.1 Inspect the support columns for thinning
Check the reinforcing pad on the bottom is seal
5.2.2 welded to the tank bottom plate with horizontal
movement clips welded to the pads
Determine if the pipe column supports are concrete
5.2.3
filled, if not they are provided with a drain hole.
Inspect the drafters for corrosion, particularly near the
5.2.4
center of the roof
5.2.5 Check for loose or twisted drafters
5.2.6 Inspect girders for corrosion and fixed properly
Page 65 of 90


Equipment data:
Page 66 of 90
Attachment: C-XI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - TANK (cont'd)

Equipment data:
5.3 Fixed roof Appurtenances
5.3.1 Inspection and light hatches
Inspect the hatches for corrosion, paint and coating
5.3.1.1
damages, holes and cover sealing
On loose covers check if the safety chain in good
5.3.1.2
condition
5.3.1.3 On light hatches check for safety rods
5.3.1.4 Check the gasket face on the hatch covers
5.4 Breathers and Vents

5.4.1 Inspect the breathers if they are functional
5.4.2 Inspect screens on vents and breathers.
5.5 Emergency P/V Hatches

5.5.1 Inspect the pressure/vacuum hatches
5.5.2 Inspect the liquid seal hatches for corrosion
5.6 Floating Roof

5.6.
Roof Deck
1
5.6.1.1 Hammer test the area between the roof rim and shell
5.6.1.2 Check the roof drain for plugging.
5.6.1.3 In sour service check all welds for cracks
5.6.
Floating roof pontoons
2
5.6.2.1 Visually check all the pontoons for leaks
Check each pontoon for vapor tight, liquid tight and
5.6.2.2
acceptable.
Inspect the lockdown hatches each cover and the
5.6.2.3
opening
5.6.
Floating Roof Cutouts
3
5.6.3.1 Inspect under side of cutouts for mechanical damage
5.6.3.2 Inspect welds for cracks
5.6.3.3 Inspect plates for thinning, pits and erosion
5.6.3.4 Measure mixer cutout and plate thickness
Page 67 of 90

Equipment data:
5.6.
Floating Roof Supports
4
Inspect fixed low and removable high floating roof
5.6.4.1
legs for thinning
5.6.4.2 Inspect notching at bottom of legs for drainage
5.6.4.3 Inspect for leg buckling or fall off at the bottom
5.6.4.4 Inspect pin hole in roof guide for tears
Page 68 of 90

Equipment data:
5.6.4.5 Check plum of all legs
Inspect for adequate reinforcing gussets on all legs
5.6.4.6
through a single portion of the roof
5.6.4.7 Inspect the roof area for cracks, etc
5.6.4.8 Inspect the sealing system and the vapor plugs
On shell mounted roof support, check for adequate
clearance based on the maximum floating roof
5.6.4.9 movement as determined by the position of the roof
relative to the gauge well and or counter rotational
device
6.0 Floating Roof Seal Assemblies

6.1 Primary shoe assembly
Remove four sections of foam log ( foam filled seals)
6.1.1 O
for inspection on 90 locations
Inspect hanger attachment to roof rim for thinning,
6.1.2
bending, weld damage etc.
6.1.3 Inspect clips welded to roof rim for thinning
6.1.4 Shoes-inspect for thinning and holes in shoe
6.1.5 Inspect for bit-metal bolts, clips and attachment
Seal Fabrics-Inspect for deterioration, stiffening, holes
6.1.6
and tears in fabrics
Measure length of fabric from top of shoe to roof rim,
6.1.7 and check the maximum annular space allowed for
roof movement
Inspect any modification of shoe over shell nozzles,
6.1.8
mixers etc., for clearance
Inspect shoes for damage caused by striking shell
6.1.9
nozzles, mixers etc.
6.2 Primary Toroidal Assembly

Inspect seal fabrics for wear, deterioration, holes and
6.2.1
tear
6.2.2 Inspect foam for liquid absorption and deterioration
6.3 Rim-Mounted Secondary’s

Inspect the rim-mounted bolting bar for corrosion and
6.3.1
weld defects
6.3.2 Measure and chart seal to shell gaps
Visually inspect from under side for holes as evident
6.3.3
by light
6.3.4 Inspect fabrics for deterioration
6.3.5 Inspect for contacts and deterioration
6.3.6 Inspect for mechanical damage, corrosion etc
Page 69 of 90

Equipment data:
Page 70 of 90

Equipment data:
7.0 Floating Roof Appurtenances
7.1 Roof Manway
7.1.1 Inspect manway wall for pitting and thinning
7.1.2 Inspect manway cover, gasket face and bolts
7.2 Rim Vent
7.2.1 Check Rim Vent for pitting and holes
7.2.2 Check the condition of vent screen
On floating roof check the vent pipe to rim joint for
7.2.3
corrosion
7.3 Vacuum Breaker, Breather Type

7.3.1 Check breather valve operations
Check the nozzle pipe projection is ½” below roof
7.3.2
deck
Inspect stem for thinning and measure how far the
7.3.3 vacuum breather cover is when raised off the pipe
when roof is resting high ,low
Roof Drains: Open System

7.4
including Emergency Drains
Check liquid level inside open roof drains for
7.4.1 adequate free board. Report if there is insufficient
distance between liquid level and top of drain
If tank comes under Air Quality Monitoring District
7.4.2
rules, inspect the roof drain vapor plug
If emergency drain is not at the center of the roof,
7.4.3
check at least there are three emergency drains
Closed Drain Systems: Drain

7.5
Basins
7.5.1 Inspect for thinning and corrosion
7.5.2 Inspect protective coating
7.5.3 Inspect basin cover or screen for corrosion
7.5.4 Test operation of check valve
Check for the presence of check valve where bottom
7.5.5
of basin is below product level
Inspect drain basin(s) to roof deck welds for cracking
7.5.6
including reinforcement pad
Closed Drain System: Fixed Drain

7.6
Line on Tank Bottom
7.6.1 Hammer test the drain line for thinning and plugging
Page 71 of 90

Equipment data:
Inspect supports & reinforcing pads for weld failures
7.6.2
and corrosion
Page 72 of 90

Equipment data:
Check that pipe is guided, not rigidly locked to
7.6.3
support, to avoid tearing of bottom plate
Closed Drain System: Flexible pipe

7.7
system
7.7.1 Inspect any external damage to pipe
7.7.2 Check for obstruction that pipe could catch
7.7.3 Inspect shield to protect pipe from snagging
Closed Drain System: Articulated

7.8
joint drain
Hammer test the rigid pipe in flexible joint system for
7.8.1
corrosion
7.8.2 Inspect system for bending or strain
7.8.3 Inspect landing legs and pads
7.9 Autogauge System and Alarms

Check free movement of tape through autogauge
7.9.1
tape guide
7.9.2 Inspect sheaves for free movement
7.9.3 Check operation checker
7.9.4 Inspect tape and tape cable for twist and fraying
Test tape’s free movement through the guide sheaves
7.9.5
and guide pipes
7.9.6 Check float for leakage
Test float guide wire anchors for spring action by
7.9.7
pulling on wire and releasing
Inspect float wells in floating roofs for thinning and
7.9.8
corrosion, just above the liquid level
Check the autogauge wire is firmly attached to the
7.9.9
float
Inspect the tape cable and float guide wire fabric
7.9.10
seals through the float well cover
8.0 Common Tank Appurtenances

8.1 Gauge Well
Inspect gauge well pipe for thinning: check for
8.1.1
thinning at the edge of the slots
8.1.2 Check for corrosion on the pipe joint:
8.1.3 Check for cone at the bottom end of pipe

8.1.4 Check the condition of well washer pipe and its flared
Page 73 of 90

Equipment data:
end point towards the hold off pad
Check that the support for gauge well welded to pad
8.1.5
or shell and not directly to the pad
Page 74 of 90

Equipment data:
8.1.6 Check operation of the gauge well cover
Check the hold off distance in well pipe and record
8.1.7
the mark.
Identify and report pipe size & schedule, whether solid
8.1.8
or slotted
Check the hold off plate is seal welded to the bottom
8.1.9
indirectly
8.1.10 Inspect the vapor control float and cable
8.1.11 Check for the presence of gauge well washer
Inspect gauge well guide in floating roof for corrosion
8.1.12
or thinning
Inspect guide rollers and sliding plates for free
8.1.13
movement
8.1.14 Inspect the seal system of the gauge well
Visually inspect inside of the pipe for weld protrusion,
8.1.15
which may catch the float.
Sampling system: Roof Sample

8.2
Hatches
Inspect roof mounted sample hatches for reinforcing
8.2.1
pad and cracking
8.2.2 Inspect cover for operation
8.2.3 Inspect sample hatch covers for proper sealing
Check alignment of internal float roof sample hatch
8.2.4
under fixed roof hatches
Inspect the sealing system on the internal floating roof
8.2.5
sample hatch cover
Inspect floating roof sample hatch cover recoil reel
8.2.6
and rope
8.3 Shell Nozzles
8.3.1 Inspect shell nozzles for pitting and thinning
8.3.2 Inspect hot tap nozzles for trimming of holes
8.3.3 Identify types of shell nozzles
Identify and describe internal piping including elbow
8.3.4
up and elbow down types
For Nozzles Extended into the

8.4
Tank
8.4.1 Inspect the pipe pads welded to the tank bottom
8.4.2 Inspect pipe is free to move with out strain
8.4.3 Inspect nozzle valves for leaks
8.4.4 Check which nozzle is fitted with thermal relief valve
8.4.5 Inspect wear plate on the down fill nozzle
8.4.6 Inspect impact of erosion in elbow up-fill in floating
Page 75 of 90

Equipment data:
roof
Page 76 of 90

Equipment data:
8.5 Diffusers and Air Rolling System
8.5.1 Inspect diffuser pipe for erosion /thinning
8.5.2 Check holes in the diffuser for wear and enlargement
8.5.3 Inspect diffuser supports for corrosion and damage
Check that diffuser supports restrain and not
8.5.4
anchored
Inspect air spiders on bottom of the lube oil tanks for
8.5.5
plugging, damage or breaking
8.6 Swing Lines

8.6.1 Inspect flexible joints for cracks and leaks
8.6.2 Inspect moving faces between swing lines
8.6.3 Check flexible joints over 6” are supported
8.6.4 Inspect swing pipes for pits and weld corrosion
8.6.5 Check for pits & leaking pontoons
8.6.6 Inspect the pull-down cables for damages
Inspect bottom mounted supports and safety hold
8.6.7
chain for integrity
9.0 Access Structure

9.1 Handrails
9.1.1 Identify and record the type of handrail
9.1.2 Inspect attachment
9.1.3 Inspect pitting, holes and paints
9.1.4 Inspect sharp edges
9.1.5 Inspect the hand rails between rollers
9.2 Platform Frames

9.2.1 Inspect platform for corrosion and paint loss
9.2.2 Inspect all attachment
9.2.3 Check the grating for damages
9.3 Deck Plate and Grating

Inspect the deck plate for corrosion, holes and paint
9.3.1
failure
9.3.2 Inspect plate to frame welds
9.3.3 Inspect grating for breakage, damage
9.4 Stairway Stringers

Inspect spiral stairway stringers for corrosion, paint
9.4.1
and weld failure
Page 77 of 90

Equipment data:
9.4.2 Inspect stairway welds to shell
Page 78 of 90


Equipment data:
Inspect steel support attachment to concrete base for
9.4.3
corrosion
9.5 Rolling Ladder

9.5.1 Inspect rolling ladder stringers for corrosion
Identify and inspect ladder fixed rungs for weld
9.5.2
attachment to stringers and corrosion
Inspect steel support attachment to concrete base for

9.4.3
corrosion
Check for wear and corrosion where rolling ladder
9.5.3
attaches to gaging flatform
9.5.4 Inspect pivot for wear and secureness
9.5.5 Inspect corrosion of moving parts
9.5.6 Inspect operation of self leveling stairway treads
9.5.7 Inspect rolling ladder wheels for free movement
9.5.8 Inspect rolling ladder alignment with roof rack
9.5.9 Inspect rolling ladder welds for corrosion
NOTES:
Page 79 of 90
Attachment D – Nomenclature And Types Of Heat Exchangers
Page 80 of 90
Different Types of Heat Exchangers
Page 81 of 90
Page 82 of 90
Page 83 of 90
Vessel
Page 84 of 90
Typical Heater Arrangement
Page 85 of 90
Fin Fan Cooler
Page 86 of 90
CRUDE HEATER
Page 87 of 90
ISOMAX REACTOR PLATFORMER REACTOR
Page 88 of 90
CRUDE COLUMN VACUUM COLUMN
Page 89 of 90
TYPICAL CONCRETE LINED AND TRAYED VESSEL
Page 90 of 90

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Inspection Procedure

00-SAIP-80 26 November 2007

Saudi Aramco DeskTop Standards

Attachment A – Flowchart-Process Equipment

Previous Issue: New Next Planned Update: TBD

Copyright©Saudi Aramco 2007. All rights reserved.

3.1 Radiographic examination personnel safety should be per SAEP-1143 paragraph

3.2 All pressure testing should be in compliance with GI-0002.102, "Pressure

4.1 Saudi Aramco References

Saudi Aramco Engineering Standards

SAES-W-015 Strip Lining Application

Saudi Aramco Engineering Procedures

Saudi Aramco General Instructions

Saudi Aramco Inspection Procedures

4.2 Industry Codes and Standards

American Society of Mechanical Engineers

American Petroleum Institute

5 Definitions and Abbreviations

Pressure Vessels: Is a container designed to withstand internal or external pressure.

Filler material: The material to be added in making metallic or nonmetallic joints.

Porosity: Cavity type discontinuities formed by gas entrapment during solidification of

Aligned Indications: A sequence of four (4) or more rounded indications should be

Hydrocarbon Services: Process streams of liquid or gaseous hydrocarbon (HC)

Low-Chrome Alloy Steels: Alloy materials with nominal chromium contents of 1% to

P&ID Piping and Instrumentation Drawings

6.1.1 Check the vessel drawing, construction code, material of construction,

Check for adequate lighting and scaffold as required for inspection.

6.1.7 While performing detailed inspection look for pitting corrosion,

6.1.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325,

SAEP-20 in advance. The test or waiver documents shall be filed for

6.2 Reactor Vessels

6.2.1 Check the reactor vessel drawing, construction code, material of

6.2.6 Start preliminary inspection at manway (manway inspection) going

6.2.7 While making a detailed inspection, look for pitting corrosion,

mechanical damages while opening and fixing, environmental

If Fitness for Service (FFS) assessment is required, a full evaluation

6.2.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325,

6.3 Platformer Reactor Vessel

6.3.6 Start preliminary inspection at manway (manway inspection) at the top

6.3.7 While performing detailed inspection, look for pitting corrosion,

If Fitness for Service (FFS) assessment is required, a full evaluation

6.3.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325,

6.4 Heat Exchangers

6.4.1 Check the Exchanger drawing, construction codes, material of shell,

6.4.7 Inspect the exchanger if adequately cleaned for inspection. If cleaning

6.4.7.3 Inspect the shell for corrosion/erosion of shell and seam

6.4.7.4 Check all nozzle condition to ensure they are free of

6.4.8 Tube bundle has to be thoroughly inspected as follows:

6.4.8.1 Inspect the tube sheets for corrosion/erosion, tube end

6.4.8.2 Go along the tube external surface, note for corrosion

6.4.10 If Fitness for Service (FFS) assessment is required, a full evaluation

6.4.14 On completion of inspection and repairs if any, hydrostatically test the

exchangers, otherwise, three tests shall be required per SAEP-317, at

6.4.15 Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010,

6.5 Reactor Effluent Heat Exchangers

6.5.1 Check the Exchanger drawing, construction codes, material of shell,

6.5.7 Inspect the exchanger if adequately cleaned for inspection. If cleaning

6.5.7.2 Inspect the channel heads and covers for corrosion/erosion,

6.5.7.3 Inspect the shell for corrosion/erosion at seam welds, shell

6.5.7.4 Check all nozzle condition to ensure they are free of

6.5.8 Tube bundle has to be thoroughly inspected as follows:

6.5.8.1 Inspect the tube sheets for corrosion/erosion, tube end

6.5.8.2 Go along the tube external surface, note for corrosion