Saep 308 PDF

Engineering Procedure
SAEP-308 22 May 2016

Operations Inspection Unit Reviews
Document Responsibility: Inspection Engineering Standards Committee
Contents
1 Scope.......................................................................... 2
2 Conflicts and Deviations.............................................. 2
3 Applicable Documents................................................ 2
4 Definitions and Abbreviations..................................... 4
5 Responsibilities........................................................... 5
6 Instructions.................................................................. 9
Appendix A - Core Assessment Areas........................... 14

Appendix B - Observations and Recommendations
Reporting Form........................................ 15
Appendix C - Status of High and Medium
Priority Observations............................... 16
Appendix D - Observations Priority................................ 17
Appendix E - Self Assessment Questionnaires…….….. 18
Appendix F - Observation Root Cause Analysis Form... 29
Previous Issue: 30 October 2014 Next Planned Update: 22 May 2019

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Contact: Lodhi, Zeeshan Farooq (lodhizf) on +966-13-8804518
Copyright©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-308
Issue Date: 22 May 2016
Next Planned Update: 22 May 2019 Operations Inspection Unit Reviews
1 Scope
1.1 This SAEP provides requirements for Inspection Department’s functional

responsibility to periodically assess the performance of inspection programs
within all Saudi Aramco operating plants, operation support facilities,
community and any other facility requested by corporate management.
A team assigned by the Inspection Department shall conduct the assessment.
1.2 The assessment specified in this SAEP shall be conducted under the Operational
Excellence Corporate Assessment Protocol.
1.3 This procedure also provides the requirements for PIU to conduct annual
self-assessment.
2 Conflicts and Deviations
2.1 Waivers
Direct all requests to waive the requirements of this Procedure in writing

according to internal company procedure SAEP-302, “Instructions for
Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement”
to the Manager, Inspection Department of Saudi Aramco, Dhahran.
2.2 Deviations
Any required deviation from the requirements of this procedure shall be

reviewed and approved according to internal company procedure SAEP-301,
“Instructions for Establishing and Maintaining Mandatory Saudi Aramco
Engineering Requirements”.
3 Applicable Documents
All mandatory standards, plus the following and their references:
3.1 Saudi Aramco References
Corporate Operational Excellence Assessment Protocol, Revision 1
Saudi Aramco General Instructions

GI-0002.600 Plant Unit Acceptance after T & I Shutdown
GI-0428.001 Cathodic Protection Responsibilities
GI-1781.001 Inspection, Testing and Maintenance of Fire
Protection Equipment
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GI-1809.001 Job Certification
Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedules
SAEP-309 Inspection of Community and Operations Support
Facilities
SAEP-318 Pressure Relief Valve Program Authorization for
RV Installation, Deletion, and Changes
SAEP-319 Pressure Relief Devices - Testing and Inspection
Requirements
SAEP-321 Performance Qualification Testing of Saudi Aramco
Welders
SAEP-325 Inspection Requirements for Pressurized Equipment
SAEP-333 Cathodic Protection Monitoring
SAEP-343 Risk Based Inspection (RBI) for Saudi Aramco
Facilities
SAEP-372 Plant Inspection Performance Index
SAEP-374 High Integrity Protection Systems - Periodic
Functional Testing Requirements
SAEP-375 High Integrity Protection Systems - SAP Tracking
System Workflows
SAEP-376 High Integrity Protection Systems - Testing and
Maintenance Reporting Requirements
SAEP-377 High Integrity Protection Systems - Personnel
Training and Qualifications
SAEP-378 Electrical Inspection Requirements
SAEP-1131 Pressure Relief Device Authorization through SAP
Workflow
SAEP-1135 On-Stream Inspection Administration
SAEP-1140 Qualification of Saudi Aramco NDT Personnel
SAEP-1142 Qualification of Non-Saudi Aramco NDT Personnel
Saudi Aramco Engineering Standards

SAES-A-206 Positive Material Identification
SAES-L-133 Corrosion Protection Requirements for Pipelines,
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Piping and Process Equipment
Saudi Aramco Inspection Procedures

00-SAIP-72 Inspection Involvement in Management of Change
00-SAIP-73 Inspection Manning Determination Guidelines
00-SAIP-75 External Inspection
00-SAIP-77 Technical Alert Implementation and Tracking
00-SAIP-78 Inspection Records/Filing
Operations Inspection Unit Procedures and Quality Manuals
Saudi Aramco Approved Inspection Job Descriptions
4 Definitions and Abbreviations
4.1 Definition of Important Terms
Community Facilities: Refer to SAEP-309
Corrective Action: An action taken to eliminate the causes of any existing

nonconformity or other undesirable situation in order to prevent recurrence.
Objective Evidence: Qualitative or quantitative information, records or

statements of fact pertaining to the quality of an item or service, or to the
existence and implementation of an inspection system or program, which is
based on observation, measurement, or test and which can be verified.
Observation: A statement of fact or findings made during an assessment and

supported by objective evidence.
Operation Support Facilities: Refer to SAEP-309
Plant Inspection Performance Index (PIPI): A tool to annually measure PIU

performance based on scoring a set of measures related to each inspection
program or function.
Root Cause Analysis (RCA): Identifies the underlying reasons why problems
occur and to avoid recurrence.
There are several methodologies for RCA and nominating any particular
methodology is beyond the scope of this document.
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4.2 Abbreviations
AJTS Assigned Job Task Specification
GI General Instruction
ID Inspection Department
IEU Inspection Engineering Unit of the Inspection Department
MSAER Mandatory Saudi Aramco Engineering References
MOC Management of Change
NACE National Association for Corrosion Engineers
NDT Nondestructive Testing
PIU Plant Inspection Unit
OE Operational Excellence
OID Operations Inspection Division
RTFI Radiography Test Film Interpreter
RV Relief Valve
SABP Saudi Aramco Best Practice
SAEP Saudi Aramco Engineering Procedure
SAER Saudi Aramco Engineering Report
SAES Saudi Aramco Engineering Standard
SAIP Saudi Aramco Inspection Procedure
SAIF SAP Application for Inspection of Facilities
SAMSS Saudi Aramco Materials System Specification
SASD Saudi Aramco Standard Drawings
HIPS High Integrity Protection System
5 Responsibilities
5.1 Inspection Engineering Unit (IEU)
5.1.1 IEU shall be responsible for coordinating the Operations Inspection

Unit assessment activities per the OE Corporate Assessment Protocols.
This coordination includes:
5.1.1.1 Scheduling the assessment as per the OE assessment schedule.
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5.1.1.2 Selection of Inspection lead Assessor for each assessment.
5.1.1.3 Selection of ID assessment team members for each OE

assessment.
5.1.1.4 Notifying involved members of their specific assignments.
5.1.1.5 Participate in the pre-assessment activities as organized by the

Operational Excellence Department.
5.1.1.6 Attending the post-assessment meeting with all corporate

entities involved in OE Assessment PIU before leaving the site.
5.1.1.7 Preparation of assessment materials/guides, such as the unit

data forms, questions for interviews, checklists, and format.
5.1.1.8 Providing input to OE Lead Assessor for the final OE

assessment report.
5.1.1.9 Issuance of ID final report to plant management.
5.1.2 IEU shall be responsible for determining the number of team members,
their discipline and their minimum qualification requirements according
to this SAEP.
5.1.3 ID Assessment Team Leader Responsibilities are;
5.1.3.1 To be the single point contact for ID Assessment team for the
assigned OE assessment area.
5.1.3.2 Selection of ID Assessment team members for assigned area
5.1.3.3 Notifying involved members of their specific assignments
5.1.3.4 Participate in the Pre-assessment, On-site and Post-assessment

meetings along with OE assessment team
5.1.3.5 Two weeks prior to the start of the assessment, brief the ID
assessment team members on all aspects of the assessment
(i.e., schedule, report format, transportation and lodging plans,
special access requirements, etc.)
5.1.3.6 Familiarize non-IEU Team members with assessment process

and basic auditing skills as replacement for training/certification
requirements.
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5.1.3.7 Prepare the preliminary report within 5 working days of receipt

of the team member reports.
5.1.3.8 Issue the final ID report to plant management within four weeks.
5.1.4 Individuals chosen as assessors have the following responsibilities:
5.1.4.1 Evaluate the PIU systems and conformance to comply with

company standards, procedures, general instructions and
reports.
5.1.4.2 Carry out assigned assessment tasks.
5.1.4.3 Comply with assessment requirements.
5.1.4.4 Respect all confidentiality requirements.
5.1.4.5 Collect and document objective evidence about the systems

conformance to existing company criteria.
5.1.4.6 Safeguard assessment documents, records, and reports.
5.1.4.7 Entering the observations into the SAIF computer program.
5.2 Operations Inspection Unit (PIU) Responsibilities
5.2.1 The PIU Supervisor shall be the primary contact for the inspection team
lead assessor for scheduling interviews related to OE Modules with
personnel in the unit.
5.2.2 Upon receiving a request from the OE assessment team leader, the PIU
Supervisor shall provide information related to his unit by completing
survey data forms that will be provided as a part of the request.
5.2.3 The PIU shall provide access to the assessment team to inspect its
facilities, interview its employees and assess its documents as requested
by the assessment team leader.
5.2.4 PIU Supervisor shall explain requirements of this SAEP to the Unit
personnel and ensure their compliance.
5.2.5 The PIU shall provide logistical support to the assessment team as
required, such as office space, access to documents, reports, staff
interviews and security permits.
5.2.6 The PIU department shall respond to assessment observations as outlined

in this SAEP.
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5.2.7 The PIU Supervisor shall schedule and conduct the annual unit self-
assessment in accordance with this SAEP and inform ID of the schedule.
As a minimum, Appendix E - Self Assessment Questionnaires shall be
used as a basis for evaluating conformance with requirements of this
procedure.
5.2.8 The PIU Supervisor shall send the self-assessment outcome report to
IEU for review as per the requirements of SAEP-372.
5.2.9 The PIU employees’ responsibilities are:
5.2.9.1 Cooperate fully with the assessment team.
5.2.9.2 Allow assessors to examine all documents, records and

facilities.
5.2.9.3 Respond to assessor’s questions so that a true representation of

the units systems, procedures and policies are provided.
5.2.9.4 Entering and update the status of the Corrective Actions and
ETCs in SAIF system at interval stipulated in this SAEP.
5.3 Operational Excellence Department Responsibilities are;
5.3.1 Coordination and liaison with the assessed department for the overall
Operational Excellence assessment.
5.3.2 Formulation of Operational Excellence assessment team with

representatives from all corporate entities as per the OE protocol.
5.3.3 Managing the pre-assessment coordination and scheduling.
5.3.4 Arranging the pre-assessment coordination meeting with all corporate

entities involved in the assessment to explain the intent of audit and
discussion on logistic arrangements etc.
5.3.5 Attending the post-assessment meeting to consolidate and present the

final outcome of OE assessment with OE compliance coordinator from
the assessed facility.
5.3.6 Agreement on overall assessment findings and categorization with

relevant units.
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6 Instructions
6.1 Assessment Objectives
6.1.1 To verify that Saudi Aramco standards and procedures are being
properly implemented along with the applicable industry standards.
6.1.2 To assess the effectiveness and functional readiness of the unit’s

inspection activities by examining its capabilities including filled
positions.
6.1.3 To review the implementation of recommendations and closure of items

following previous PIU or OE assessments and other technical audits.
6.1.4 To identify and share good inspection practices company-wide.
6.2 Scheduling of Operations Inspection Unit Assessments
6.2.1 The PIU Assessments shall be planned as part of the Operational

Excellence Assessment protocol.
6.2.2 All PIUs are required to conduct an interim internal self-assessment

annually to assess their strengths and areas of improvement in all
inspection programs listed in Appendix A.
6.2.3 The outcome of this assessment and internal self-assessment shall be

used in an annual company-wide performance evaluation based on
SAEP-372, Plant Inspection Performance Index (PIPI).
6.2.4 On the basis of the PIPI performance, if an assessment is judged by the

Inspection Department to be required before the normal three years
schedule, the Inspection Department shall inform the Proponent of the
need for partial or complete assessment at a time which is earlier than the
3 year cycle. This requirement shall be coordinated through Operational
Excellence department.
6.2.5 The operating facility manager can also, on the basis of the PIPI
performance, propose a partial or complete assessment earlier than
3 years. The requirement shall be coordinated through Operational
Excellence department.
6.3 Preparation for Assessment
6.3.1 Preliminary PIU Data Gathering
Before the start of the OE assessment, the PIU Supervisor shall provide
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information and documentation about his unit work processes. This data
shall be shared by OE lead assessor with all the team members to review,
analyze and plan their part of assessment activities.
6.3.2 Assessment Team
6.3.2.1 An assessment team shall be assembled based on individual

expertise in the areas to be assessed.
6.3.2.2 First time assessors should accompany senior members, who

must review their input.
6.3.2.3 The Inspection Lead assessor should have good writing skills
and should have previously participated in assessment reviews.
6.3.2.4 The inspection team may comprise up to 25% from other

operating facilities or non-ID engineering services department
to join the assessment team.
6.3.3 The Team members from other departments should be determined and
requested at the time of planning the reviews for the upcoming year.
6.3.4 Assessment assignments shall be made based on each team members’

area of expertise. Assignments shall be made for evaluating each of the
following inspection functions and programs against the associated
procedures and applicable standards listed in Appendix A.
6.4 PIU Field Assessment
6.4.1 Field assessment shall be between 3 to 5 days depending on the facility

size, performance and geographical location.
6.4.2 To begin the field assessment, the IEU assessment team shall have a
kick-off meeting with the PIU personnel. The PIU should prepare a
presentation that gives an idea about the facility size, process,
manpower, areas of concerns for the team to focus. The inspection lead
assessor shall introduce the team members and clearly state the objective
of the assessment. The schedule and plans shall also be discussed with
the PIU Supervisor who shall coordinate the work of his personnel to
make them available for interviews.
6.4.3 The PIU shall arrange for a walkthrough of the facility or part of it, as
agreed with the inspection lead assessor prior to the assessment, to verify
compliance with the standards and procedures and to verify the
effectiveness of the PIU inspection programs.
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Commentary Note:
This is not a punch listing exercise and is aimed at collecting objective

evidence of strengths, non-conformances or areas of improvement using
checklists for guidance for each program. These will be used to cross-
check the records and during interviews with Unit personnel and be cited
as examples when writing non-conformances or observations.
6.4.4 Team members shall conduct interviews, inspect testing and measuring
equipment, facilities, reference materials and programs in accordance
with their specific assignments. They shall be guided in the assessment
by the prepared interview questions and references in Appendix A but
shall not be limited to them if additional investigation is deemed
necessary for a thorough evaluation. They shall document their findings
in the format shown in Appendix B.
6.4.5 At the end of the field assessment, the team shall brief the PIU Supervisor
and OE team leader on observations with immediate, high and medium
priority before presenting them to the proponent management and issuance
of the final report.
6.5 Assessment Reporting
6.5.1 Immediately after completing the field assessment but no more than two
days after the field assessment, team members shall enter their
observations, impact, category of the observation and the
recommendation in the shared folder. All reports shall be written
following prepared template which shall include;
6.5.1.1 Observation with brief description, objective evidence,

reference standard and location of plant where finding was
made (if applicable).
6.5.1.2 Observation Impact
6.5.1.3 Observation Priority (see Appendix D for guidelines)
6.5.1.4 Recommendation
6.5.1.5 Recommendation Category – (Engineering/Design,

Equipment/Technology, Manpower, Training, or Work
Process)
6.5.1.6 New or Repeat Observation
6.5.2 The Inspection lead assessor will prepare the preliminary report within
5 working days of receipt of the team member reports.
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6.5.3 After completion of the field assessment, the final ID report will be
issued to plant management within four weeks.
6.6 Implementation and Tracking Process
6.6.1 Upon receipt of the report, the PIU Supervisor shall develop corrective
action to close each trackable observation item with an estimated to
complete (ETC) dates for all items. This corrective action shall be
agreed by the assessor to facilitate closure of the items. Corrective
actions shall include:
 Action to close reported observation
 Plan to survey facility for similar observations
 Root Cause Analysis (RCA) plan according to Appendix F
 Action plan linked to RCA recommendations to prevent
repeat/re-occurrence of reported observation
6.6.2 The agreed corrective actions along with ETC for each item shall be
submitted through SAIF system within a month from submittal of the
final report.
6.6.3 The PIU shall track the implementation of all trackable observation items
through SAIF system. When the pending items are not completed on the
ETC date, SAIF system will automatically issue a letter of non-
conformance. The non-conformance letter shall be issued progressively to
higher level of management as follows:
6.6.3.1 Division head or Superintendent or General Supervisor at

one (1) day after the due date.
6.6.3.2 PIU Department Manager, operating facility at thirty (30) days

after the due date.
6.6.3.3 Admin Area head at sixty (60) days after the due date and
continue at this reporting level at 30 days interval until the
observations resolved.
6.6.3.4 If the original estimated date of completion needs to be revised,

the division head approval for the first revision and the
department head approval for the second revision are required.
Further revision for high and medium priority observations
shall be approved by the admin area head.
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6.6.3.5 ETC Revisions:

a) The first ETC revision approved by Division Head shall
not exceed a period of six months from the original ETC.
b) The second ETC revision approved by the Department
Manager shall not exceed a period of six months from the
first revised ETC.
c) Any revision which allows a high or medium priority item
to become twelve (12) months overdue from its original
ETC shall be approved by the Admin Area Head.
d) Implementation progress shall also be monitored through
the Plant Inspection performance Index (PIPI).
6.6.4 If the PIU disagrees with or is unable to comply with a high or medium
priority observation as defined in Appendix D, the following applies:
6.6.4.1 A clarification letter shall be sent to Manager, Inspection

Department from the PIU Department’s Manager at the time of
the corrective action submittal mentioned under paragraph 6.6.1.
6.6.4.2 The PIU department manager’s letter shall state the

justification for non-compliance.
6.6.4.3 If this letter is not accepted by ID, PIU shall obtain an admin
area head clarification letter.
6.6.5 The PIU shall close all the high and medium priority observations
identified in the final report and upload in SAIF system.
6.6.6 Progress on closing the observations within ETC shall be factored in the
Plant Inspection Performance Index (PIPI) according to SAEP-372.
6.6.7 Verification of observations implementation shall be performed as part

of subsequent OE assessments and the internal self-assessment. Each
report shall indicate if the observation is repeated from the previous
assessment.
Revision Summary
22 May 2016 Major revision to address recommendations from the “Fire Investigation Report of Al-Jebel
Complex at Udhailiyah Camp”.
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Appendix A - Core Assessment Areas
Item Assessment Area Reference Assessor

1 Technical Administration Job Description, 00-SAIP-73
2 Worksheets 00-SAIP-76
Management of
3 00-SAIP-77
Recommendations
4 Positive Material Identification 00-SAIP-07
SAEP-1135, 01-SAIP-01, 00-SAIP-74,
5 On-Stream Inspection
00-SAIP-75, 01-SAIP-04
6 Plant Record Books and Files SAEP-122, 00-SAIP-78
Equipment Inspection
7 SAEP-20, GI-0002.600, SAEP-309
Schedules
SAEP-318, SAEP-319, SAEP-1131,
8 Relief Valve Program
SAEP-1132, SAEP-1133, and SAEP-1134
SAEP-1140, SAEP-1141, SAEP-1142,
9 NDT Operations SAEP-1143, SAEP-1144, SAEP-1145 and
SAEP-1146
SAES-L-133, SAEP-1135 and Corrosion
10 Corrosion Program Management Program, GI-0428.001,
SABP-A-033, SAES-L-133
Plant and Equipment
11 SAEP-325, SAEP-317 and 32-SAIP-11
Inspection
12 Welding Inspection SAEP-321, SAEP-322 and SAEP-323
13 Electrical Inspection SAEP-378, SAEP-309
14 Civil Inspection SAEP-309
15 Coatings Inspection SAEP-316
16 Training Program AJTS, GI-1809.001 and Job Description
Involvement in
17 00-SAIP-72
Management of Change
Cathodic Protection (CP) SAEP-333, and Plant Corrosion Control
18
Monitoring Program Manual, GI-0428.001
Risk Based Inspection (RBI)
19 SAEP-343
Program
20 SAIF Utilization SAEP-372 Appendix-G
Inspection Technology
21 SAEP-372 Appendix-J
Utilization
High Integrity Protective SAEP-354; SAEP-373, SAEP-374,
22
Systems (HIPS) Program SAEP-375, SAEP-376, SAEP-377
23 Non-metallics Program SAES-L-620, SAES-L-650
Community & Operations
24 SAEP-309
Support Facilities
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Appendix B - Observations and Recommendations Reporting Form
Observation
(Description, Impact of Priority Recommendation
Report Repeat/
reference and the (SAEP-308 Recommendation Category
Item # New
plant location) Observation Appendix D) (SAEP-308)
(SAEP-308)
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Appendix C - Status of High and Medium Priority Observations
(Operations Inspection Unit Name)
(Date )
ETC Revised
Corrective Action
Report Observation (To be completed ETC
to be taken Status
Item # (SAEP-308, 6.4.4 & 6.5.1) first month) (SAEP-308,
(SAEP-308, 6.6.1)
SAEP-308, 6.6.2 6.6.3)
In Progress
1
Completed
Date:
…../…../
In Progress
2
Completed
Date:
…../…../
In Progress
3
Completed
Date:
…../…../
In Progress
4
Completed
Date:
…../…../
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Appendix D - Observations Priority
Observation
Description Priority
Category
Observation deemed too critical to wait until the issuance of the final
report. The item shall be communicated to Operations Inspection Unit
Supervisor and copied to his management by individual memos so that
308-1 they can be implemented without delay. The memo shall also be attached Immediate
to the final report. This category covers all:
 Imminent safety risk items
Observation that falls under any of the following:
 Violation of a Saudi Aramco General Instruction (GI).
 Violation of a Saudi Aramco Standard, Engineering Procedure, Materials
Specification or Standard Drawing requirement (SAES, SAEP, SAMSS
or SASD).
308-2 High
 Violation of a Mandatory Saudi Aramco Engineering Requirement
(MSAER) and applicable International Design & Inspection codes.
 Deficiencies making the inspection program ineffective such as
inadequate or unavailability of manpower, inadequately trained
inspectors, inadequate inspection tools, etc.)
Observations that are considered to have a long term effect on plant
integrity and if left unattended, could possibly become a major impact item
with respect to reliability and safety. This category covers any of the
following:
 Non-conformance with Saudi Aramco Inspection Procedure (SAIP)
308-3 requirement. Medium
 Non-conformance with a Saudi Aramco Best Practice (SABP)
recommendation.
 Non-conformance with a Saudi Aramco Engineering Report (SAER)
recommendation.
Any observation that falls under any of the following:
 Non-conformance with a Saudi Aramco Inspection Manual
Recommended
recommendation.
Good Practice TBD
(RGP)  Observation and Recommendation followed by a Saudi Aramco high
performing inspection unit and judged by the assessor as a practice
which will increase the effectiveness of the assessed PIU.
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Appendix E - Self Assessment Questionnaires
E.1: Technical Administration
Does the unit conduct a study of the workload and experience level as per 00-SAIP-73
1. during business plan to decide the number of inspectors and Supervisors and whenever
new plants are added?
2. Is the Supervision assignment continuous?
Does the unit Field Supervisor(s) have adequate field experience and is meeting all job
3.
ladder qualification requirements?
4. What is the average experience level in the Unit?
Does the Unit have up-to-date written orientation Program for new inspectors based on
5.
SMS?
Has an incident or unplanned shutdown taken place that was found to be a result of
6.
inspection program failure since the last assessment?
Does the Inspection Unit participate in all Management plant walkthrough inspections
7.
and participate in the review meetings?
8. Does the unit conduct at least monthly safety/communication meetings?
9. Has the unit conducted the annual self-assessment?
10. Does the unit have approved and communicated KPIs for all inspection programs?
11. Does unit inspectors attend or track OME meeting items for their area?
E.2: Worksheets/Defect Notifications (DN)

1. Do you use SAIF for Tracking defect notifications?
2. Do you reference standards in your DNs?
Is the DN kept open for temporary repair until it is properly reviewed as permanent or
3.
permanent repair is done?
4. Are critical and outstanding DNs highlighted monthly to plant manager?
Does the unit Supervisor conduct quarterly defect notification review meeting with
5.
operations?
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E.3: Management of Recommendations

1. Do you have a system to track Technical Alerts?
2. Do you have a system for tracking self-assessment observations?
Is there a system for tracking and follow up on recommendations issued for proper and
3.
timely completion such as PZV shop audit observations?
4. Are OID Assessments Status reports issued on time to the Inspection Department?
5. Do you have any OID Assessment observations exceeding the ETC?
E.4: Positive Material Identification (PMI)
1. Is PMI inspection done by the Unit on received material?
2. Do you have a PMI machine?
3. Is PMI of alloy material verified after fabrication?
4. Is SAES-A-206 followed for marking, reporting and documentation?
5. Is existing low alloy piping/equipment PMI spot checked during T&Is?
6. Is PMI machine calibrated as per manufacturer recommendations?
E.5: On-Stream Inspection
1. Do you have an individual coordinating the On-Stream Inspection?

2. Do you use SAIF to monitor the OSI Data?
Do you have OSI drawings for all equipment and piping in hydrocarbon service or
3.
critical service?
Does the inspection Unit have a system to ensure modifying OSI isometric drawings
4.
when changes are made to plant?
5. Do you use SAIF to track & monitor the Nipple surveys?
6. Do you use SAIF program to monitor the chemical injection points?
7. Are dead legs identified and being monitored by SAIF?
Do you conduct periodic inspection of the transition area soil/air interface) and splash
8.
zones?
9. Are all your equipment up-to-date with their CML’s (i.e., No backlog)?
10. Have all your new plants had CML’s baseline readings?
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E.6: Filing and Records
1. Is there a clerk in the Unit?

2. Is 00-SAIP-78 followed to set guidelines for record keeping, retention, indexing, etc.?
3. Are Equipment Files updated/complete?
4. Are Aramco reports format used always (NDT, HT, etc.)?
5. Do you have an up-to-date master list of all equipment?
6. Do you use SAIF to store inspection history?
7. Are all Deviation requests and discretionary letter available?
8. Are critical records properly protected (e.g., fireproof cabinet) or electronically backed up?
9. Do you have all reference material in the Unit if not available through the Intranet?
E.7: Equipment Inspection Schedule
1. Are all pieces of equipment included in the EIS as required SAEP-20?

2. Are deviation requests submitted to the Inspection Department complete?
3. Do you issue quarterly report for due and overdue equipment?
4. Is the discretionary letter for due equipment issued timely?
Do you use SAIF to track the EIS and add reminding capabilities for Operations and T&I
5.
Planning?
6. Have you completed initial T&I for all new equipment per SAEP-20?
7. Have you complied with the external inspection requirement as per SAEP-20?
8. Do you have an active RBI program to optimize inspection?
9. Are EIS period adjusted based on T&I findings?
10. Are road crossing inspection & revalidation conducted per EIS?
11. Is a sub-sea pipeline inspection program functional?
12. Are all Operations Support Facilities listed and inspected per EIS?
13. Are mothballed equipment identified and monitored per SAEP-20 and SAER-2365?
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E.8: Relief Valves

Is a Quality manual for PZV available in the maintenance shop and followed? If not has
1.
the unit highlighted deficiencies to management?
Are all your RVs tested within EIS (i.e., none overdue without approved deviation
2.
request per SAP RV System)?
3. Do you physically check rupture discs for integrity?
4. Do you physically check rupture pins for integrity?
5. Are annual internal audits conducted on maintenance shops per schedule?
Do you conduct annual survey to ensure that installed RVs are tagged, sealed, in the
6.
correct location, and piped to a safe location?
Do the identification tags of all the RVs contain information related to RV number, T&I
7.
date, next T&I date and test pressure?
Do you participate in the two-years comprehensive physical review conducted jointly
8.
with Operations Supt., & Engineering?
9. Are mothballed RV properly designated and tracked?
Do you highlight any RV for potential testing intervals adjustment based on SAP
10.
recommendation?
11. Are valves open to atmospheres regularly checked for open drain?
Do you have a tracking system for high integrity protection systems (HIPS) in your
12
facilities?
13 Does the unit have a RV coordinator?
14 Are all Tank Breather Valves tested and inspected according to SAEP-319 Appendix D?
E.9: Non-Destructive Testing

1. Do you use SAP to track NDT personnel performance for certification validation?
2. Is contractor personnel qualification tracked?
3. Does the Unit have enough NDT equipment and material available?
4. Do you have a documented program for calibrating NDT instruments?
5. Does the unit have certified level II RTFI?
6. Does the unit have a dark room available? If Applicable.
Page 21 of 29
E.10: Corrosion Management

1. Does the unit/division have a competent corrosion engineer and CP specialist?
Is Corrosion Engineer involved in OSI program and does he periodically trend/assess
2.
corrosion data?
3. Is failure analysis conducted on all failures that impact reliability or safety?
Do you monitor and document heaters in the creep range for metallurgical aging, creep
4.
and/or creep cracking?
5. Do you perform thermography for monitoring hot spots and refractory damage?
Are piping and equipment susceptible to Corrosion Under Insulation and fireproofing
6.
identified and being monitored by SAIF?
7. Does the unit have NACE CP level I certified inspector?
Do you have limits established for all key and critical process variables that affect
8. corrosion and materials degradation, and are they documented in the operating
instructions?
Do you include the corrosion impact in your management of change process, including
9.
feed change, throughput, plant modification, EIS modification, temporary repairs, etc.?
10. Is there a leak reporting system documenting all leaks?
Is there a system in place to assure that equipment susceptible to environmental cracking
11. (amine, caustic, wet H2S, deaerators) inspected at appropriate intervals with appropriate
NDT method?
Do you have a unit-specific Corrosion Management Program in place for each of your
12.
existing processing units? How is the compliance monitored?
13. Do you have effective CP for your Tanks, sub-sea structures and buried piping?
Are damage mechanisms other than pitting and general thinning reviewed by a corrosion
14.
engineer during set up of the inspection plans?
Is the yearly and quarterly schedule as applicable for monitoring the CP system available,
15.
implemented and reported?
16. Is the SAEP-333A survey report forms utilized for the CP system survey?
17. Is the low potential reading and/or the CP system deficiencies reported and tracked?
18. Is the capacity test for the solar system performed every 2 years?
19. Is the result of the CP inspection communicated to the inspection Units if done by others?
Describe monitoring process of corrosion probes? Are corrosion rates given by probes
20.
compared with OSI data and is it used to adjust corrosion inhibitor dosage?
Does your facility monitor chemical and water injection rates and correlate with
21.
thinning/failure rates?
What are your specific KPI targets established for Chemical Injection vendor? Do you
22.
review KPI target deviations with the vendor in regular review meetings?
Page 22 of 29
E.10: Corrosion Management

23. How the Corrosion Engineer is involved in review of T&I workscope?
Demonstrate if PIU contributes in Turnaround Scope Challenges to ensure all inspection
24.
activities for all damage mechanisms are accounted for?
E.11: Mechanical Inspection (Plant & Equipment)

1. Are pressure vessels being inspected by API certified inspectors or by inspectors having
more than 20 years inspection experience?
2. Are tanks being inspected by API certified inspectors or by inspectors having more than
20 years inspection experience?
3. Are piping and pipelines being inspected by API certified inspectors or by inspectors
having more than 20 years inspection experience?
4. Is susceptible flare lines checked during T&I for fouling to ensure adequacy for
emergency relief?
5. Is a checklist being utilized when conducting external inspection?
6. Have all assigned inspectors completed the AJTS for all mechanical jobs?
7. Is being followed all the time when inspecting pressurized equipment?
8. Are the mechanical inspection tools available to perform the required mechanical
inspections (e.g., flash light, pit gauge, hammer, magnet, magnifying glass, etc.)
9. Is the external inspection required by SAEP-20 being performed timely (no overdue)?
10. Is inspection formally informed of maintenance activities such as during OME meetings?
E.12: Welding/Repair Inspection
1. Are all welding jobs inspected by certified welding inspectors?

2. Do you use a Welder Tracking System?
3. Do you enter welder performance in the WTS?
4. Do you utilize certified shops for ASME vessels alterations?
5. Are welding inspection tools available?
6. Are shop and field weld inspection covered and roles specified?
7. Do you conduct periodic assessment on your welding shops?
Have you issued Job Clearance Cards (JCC) to your contract welders and are they up to
8.
date?
Page 23 of 29
E.13: Electrical Inspection

1. Is the electrical inspection performed by qualified inspectors?
2. Does the unit have a back-up electrical inspector?
3. Is the electrical inspection required by SAEP-20 being performed timely (no overdue)?
4. Does the electrical inspector have tools and technical resources?
5. Is the unit informed of all electrical activities (daily/weekly schedule)
6. Do you verify that cable splicing is done by certified cable splicers?
7. Do you perform periodic junction box surveys?
8. Do you maintain a file of plant electrical drawings and equipment manuals?
Do you conduct special electrical inspection programs such as Infrared scanning of
9.
electrical equipment and/or x-ray of conduit seal fittings?
E.14: Civil Inspection

1. Do use SAIF to monitor the civil inspection activities?
2. Has the civil inspector completed the AJTS for civil inspections?
3. Do you perform periodic inspection on the plant structure and foundations?
4. Is there an API 936 certified refractory inspector available?
Do you utilize SAIF to list and monitor the inspection for concrete structures and
5.
fireproofing in your plants (both onshore and offshore)?
Do you make sure that the 3rd party testing agencies for civil tests (e.g., soil test,
6.
compaction test...) are approved by the company?
Do you review the underwater inspection report for the offshore structure and issue the
7.
proper inspection recommendations?
Do you grade the concrete deterioration and failure as per the classification described in
8.
Saudi Aramco standard?
9. Do you inspect bolts and guy wires for stacks and flares for structural soundness?
10. Do you use the checklists for concrete pre-pour inspection, during pouring, etc.?
Do you follow up with the laboratory results of the concrete compressibility tests and
11.
keep records in the file?
12. Are sufficient civil inspection tools available?
13. Does the unit have a back-up civil inspector?
14. Is the civil inspection required by SAEP-20 being performed timely (no overdue)?
Do you make sure that the concrete supplier is approved by the Vendor Inspection Unit,
15.
Dhahran?
Page 24 of 29
E.14: Civil Inspection

16. Is the unit informed of all civil activities (daily/weekly schedule)?
Do you perform cement based grout strength test, Epoxy grout Test, Refectory test, as per
17.
Saud Aramco engineering Standards?
Do you perform random checks for concrete fireproofing by proper NDT method to
18.
inspect the condition of the surfaces underneath the fireproofing material?
E.15: Coating Inspection
1. Are blasters and painters certified by a Level II coating inspector?

2. Are all coating inspection performed by certified inspectors?
3. Is holiday testing conducted on all critical coating?
4. Are major and premature coating failures investigated and results documented?
5. Are coating jobs QA forms filled in and filed?
Are sufficient coating inspection tools available to inspect the blasting & coating
6.
operations?
Does the PIU have a Coating Management Program, documenting all internal/external
7. coatings with application date, type, applicator details, operating & process conditions,
coating actual service life, coating expected life etc.?
E.16: Training & Certifications
1. Does the unit have an individual to coordinate inspector training?

2. Is the AJTS training program implemented in the Unit?
3. Does the unit have certified mentors to verify and sign off tasks?
4. Does the unit have certified evaluators to record & credit the AJTS task?
Is there a written schedule for in-house training that includes scheduling technical
5.
presentations to be shared in the unit level?
6. Does the Unit have updated Individual Development Plans (IDP) for each inspector?
Do all unit inspectors meet their current Grade Code requirements in: AJTS tasks,
7.
required certification, & ITC academic requirements?
Does the unit have a system for regularly informing its inspectors of the revised Standards
8.
and procedures?
9. Do all inspectors have at least one week inspection training courses per year?
Page 25 of 29
E.17: Involvement in Management of Change (MOC)

Is the Inspection Unit involved in the Management of change (MOC) for issues affecting
1.
equipment integrity?
Does the Unit get involved in the review of all relevant design packages, repair and
2.
modifications?
Does the Unit get involved in periodic meeting with operations, maintenance and
3.
Engineering (OME) on equipment integrity related issues?
4. Is GI-0002.600 being followed for acceptance of Units after T&I?
5. Do you have system to track the MOC requests?
6. Does the unit organize in-house MOC involvement training?
7. Does the unit have at least two personnel formally trained in MOC requirements?
8. Are the majority of unit inspectors trained in MOC involvement?
E.18: Cathodic Protection (CP) Monitoring
1. Does the unit organize in-house CP knowledge sharing sessions?

2. Does the unit have at least two inspectors trained in CP monitoring?
3. Does the unit have adequate functional and calibrated CP monitoring equipment?
4. Does the unit have CP Defect Notifications which are outstanding for over one year?
Are all the required CP surveys completed and reports issued with notification to all
5.
required by standard?
E.19: Risk Based Inspection

1. Does the unit organize in-house RBI knowledge sharing sessions?
Are adequate unit personnel trained in RBI methodology and have attended the PEDD
2.
RBI course?
3. Does the unit have a dedicated and an alternate RBI Facilitator?
Is the completion percentage of required initial RBI assessments per unit on target to
4.
meet business plan objective?
5. Are corrosion loops approved as required by standard, SAEP-343?
6. Is the last RBI inspection plan completed?
7. Is RBI facilitator involved in MOC once RBI is implemented?
8. What is the completion percentage of RBI recommendations?
Does the unit have a formal process for highlighting RBI recommendations to
9.
management and tracking implementation?
Page 26 of 29
E.19: Risk Based Inspection

10. Has the unit performed any updates or evergreening for completed RBI assessments?
11 Does the unit use RBI risk results to optimize the number and location of CMLs?
12 Does the unit have its shortlist of approved and acceptable RBI service providers?
E.20: SAIF Utilization
1. Does the unit organize in-house SAIF utilization training?

2. Are the majority of unit inspectors trained in SAIF usage?
3. What is the percentage of EIS module usage for the unit as per SAEP-372 requirement?
4. What is the percentage of OSI module usage for the unit as per SAEP-372 requirement?
5. What is the percentage of Defect Notifications module usage for mechanical, electrical
and civil defect notifications in the unit?
6. What is the percentage of leakage module usage vs. documented leaks for the department?
7. What is the ratio of number of modules used to number of relevant modules for the unit?
8. Is the unit using SAIF to trend inspection data?
E.21: Inspection Technology Utilization
1. Does the unit organize in-house inspection technology knowledge sharing sessions?
Does the unit have adequate functional and calibrated inspection technology equipment
2.
applicable for its challenges?
Does the unit have at least two inspectors trained in inspection technology equipment it
3.
owns?
Does the unit organize its inspection challenges according to requirement of ID
4.
Inspection Technology Unit?
Has the unit addressed all its Category A challenges?
5.
Category A challenges are those that have an existing solution locally.
E.22: High Integrity Protection Systems (HIPS)
1. Are all the departments HIPS validated by the corporate HIPS Committee? If applicable.
2. Are all the department HIPS tracked in SAP?
3. Does the unit organize in-house HIPS knowledge sharing sessions?
4. Does the unit have at least two trained HIPS Coordinators?
5. Are all HIPS functional testing occurring as require by standard?
Page 27 of 29
E.23: Non-metallics
Does the unit maintain a register and equipment files for all installed nonmetallic in the
1.
department? If applicable.
Is in-service inspection and condition monitoring of nonmetallic occurring as per
2.
manufacturer’s recommendations?
3. Does the unit organize in-house installed non-metallics knowledge sharing sessions?
4. Does the unit have at least two inspectors trained in nonmetallic condition monitoring?
Does the unit have adequate functional and calibrated condition monitoring equipment
5.
for its installed non-metallics?
E.24: Community & Operations Support Facilities
Approved Equipment Inspection Schedule (EIS) is maintained for Community &

1.
Operation Support Facilities as per templates of SAEP-309 Appendices?
Electrical Inspection scheduled and conducted on a 12, 24, or 36 Months basis in
2.
accordance with EIS form DE-093684 (SAEP-309 Appendix E.1)?
Civil/Structural Inspections scheduled and conducted every FIVE years in accordance
3.
with EIS form DE-069699 (SAEP-309 Appendix E.2.1)?
Plumbing Inspections made every TWO years in accordance with EIS Form No.
4.
DE-069700 (SAEP-309 Appendix E.3)?
Relief Valves and all Pressure Relief Devices tested and inspected following the
5.
requirements of SAEP-319?
Fire Safety systems and all related hardware inspected and tested as per relevant
6.
guidelines under GI-1781.001?
Page 28 of 29
Appendix F - Observation Root Cause Analysis Form
Supervisor: Date:
Log On ID: _____________________________
1. Observation –( including
location and standard
violated):
2. Root cause (explain)
3. Repeated (Yes /No)
4. Observation eliminated
(Yes /No) & how
5. Survey performed
(Yes /No)
6. Action plan to prevent

recurrence (explain)
Page 29 of 29

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Engineering Procedure

SAEP-308 22 May 2016

Appendix A - Core Assessment Areas........................... 14

Previous Issue: 30 October 2014 Next Planned Update: 22 May 2019

Copyright©Saudi Aramco 2016. All rights reserved.

1.1 This SAEP provides requirements for Inspection Department’s functional

2 Conflicts and Deviations

Direct all requests to waive the requirements of this Procedure in writing

Any required deviation from the requirements of this procedure shall be

All mandatory standards, plus the following and their references:

3.1 Saudi Aramco References

Corporate Operational Excellence Assessment Protocol, Revision 1

Saudi Aramco General Instructions

GI-1809.001 Job Certification

Saudi Aramco Engineering Procedures

Saudi Aramco Engineering Standards

Piping and Process Equipment

Saudi Aramco Inspection Procedures

Operations Inspection Unit Procedures and Quality Manuals

Saudi Aramco Approved Inspection Job Descriptions

4 Definitions and Abbreviations

4.1 Definition of Important Terms

Community Facilities: Refer to SAEP-309

Corrective Action: An action taken to eliminate the causes of any existing

Objective Evidence: Qualitative or quantitative information, records or

Observation: A statement of fact or findings made during an assessment and

Operation Support Facilities: Refer to SAEP-309

Plant Inspection Performance Index (PIPI): A tool to annually measure PIU

5.1 Inspection Engineering Unit (IEU)

5.1.1 IEU shall be responsible for coordinating the Operations Inspection

5.1.1.1 Scheduling the assessment as per the OE assessment schedule.

5.1.1.2 Selection of Inspection lead Assessor for each assessment.

5.1.1.3 Selection of ID assessment team members for each OE

5.1.1.4 Notifying involved members of their specific assignments.

5.1.1.5 Participate in the pre-assessment activities as organized by the

5.1.1.6 Attending the post-assessment meeting with all corporate

5.1.1.7 Preparation of assessment materials/guides, such as the unit

5.1.1.8 Providing input to OE Lead Assessor for the final OE

5.1.1.9 Issuance of ID final report to plant management.

5.1.3 ID Assessment Team Leader Responsibilities are;

5.1.3.2 Selection of ID Assessment team members for assigned area

5.1.3.3 Notifying involved members of their specific assignments

5.1.3.4 Participate in the Pre-assessment, On-site and Post-assessment

5.1.3.6 Familiarize non-IEU Team members with assessment process

5.1.3.7 Prepare the preliminary report within 5 working days of receipt

5.1.4 Individuals chosen as assessors have the following responsibilities:

5.1.4.1 Evaluate the PIU systems and conformance to comply with

5.1.4.2 Carry out assigned assessment tasks.

5.1.4.3 Comply with assessment requirements.

5.1.4.4 Respect all confidentiality requirements.

5.1.4.5 Collect and document objective evidence about the systems

5.1.4.6 Safeguard assessment documents, records, and reports.

5.1.4.7 Entering the observations into the SAIF computer program.

5.2 Operations Inspection Unit (PIU) Responsibilities

5.2.6 The PIU department shall respond to assessment observations as outlined

5.2.9 The PIU employees’ responsibilities are:

5.2.9.1 Cooperate fully with the assessment team.

5.2.9.2 Allow assessors to examine all documents, records and

5.2.9.3 Respond to assessor’s questions so that a true representation of

5.3 Operational Excellence Department Responsibilities are;

5.3.2 Formulation of Operational Excellence assessment team with

5.3.3 Managing the pre-assessment coordination and scheduling.

5.3.4 Arranging the pre-assessment coordination meeting with all corporate