01 Vol2part2 - Plant Inspection

VOLUME 2 – PLANT INSPECTION PROCEDURES
GENERAL
Procedure Number: PLTIP-001-GEN
KUWAIT OIL COMPANY
INDUSTRIAL SERVICES GROUP

INSPECTION AND CORROSION TEAMS
BY
CC TECHNOLOGIES
Contract No. 10626
KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
GENERAL
PROCEDURE NUMBER: PLTIP-001-GEN
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 21/07/03
Next Review Date: DD/MM/YY Page ii of iii
REVIEWER LOG:
Name, Title, Team Signature Date Signed
Approver:
Approver:
Reviewer:
Reviewer:
Reviewer:
Reviewer:
Originator:
KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

GENERAL
Next Review Date: DD/MM/YY Page iii of iii
REVISION LOG:
Revision Revision Authority Revisor Brief Description of
Number Date Revision
##### DD/MM/YY
DOCUMENT CONTROL LOG:

Controlled Copy #### of ##### Issued to: Name/Title/Team
Review Frequency Annually (Unless otherwise noted)
Computer/Location Reference To Be Determined
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Distribution List: Name/Team
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Next Review Date: DD/MM/YY Page 1 of 35
PAGE
NO.
1.0 PURPOSE..................................................................................................................... 2
2.0 SCOPE.......................................................................................................................... 3
3.0 RESPONSIBILITIES.................................................................................................. 6
3.1 KOC GENERAL
3.2 KOC INSPECTION AND CORROSION TEAM
3.3 KOC SENIOR ENGINEER
3.4 KOC INSPECTORS
3.5 OUTSIDE INSPECTION ORGANIZATION
4.0 TRAINING AND QUALIFICATIONS..................................................................... 8
5.0 PROCEDURES............................................................................................................ 8
5.1 OBJECTIVES
5.2 SAFETY PRECAUTIONS
5.3 INSPECTION PROGRAM
6.0 DATA REQUIREMENTS .........................................................................................13
7.0 REFERENCED DOCUMENTATION.....................................................................13
7.1 REFERENCES
7.2 RELATED STANDARDS
7.3 INDUSTRY STANDARDS
8.0 APPENDICES.............................................................................................................17
APPENDIX A – FIGURE A.1, INSPECTION RESPONSIBILITY (SIMPLIFIED)
CHART
FIGURE A.2, INSPECTION AND CORROSION (I&C) TEAM (NW)
ORGANIZATION CHART
FIGURE A.3, INSPECTION AND CORROSION (I&C) TEAM (SE)
ORGANIZATION CHART
APPENDIX B – FIGURE B.1, KOC MECHANICAL INTEGRITY MANAGEMENT
PLAN PROCESS
APPENDIX C – FIGURE C.1, KOC EQUIPMENT/FACILITY INSPECTION FLOW
CHART
APPENDIX D – FIGURE D.1, INSPECTION ASSESSMENT FLOW CHART
APPENDIX F – TABLE F.1, ON-STREAM INSPECTION CHECKLIST – PLANT
COMPONENTS
KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

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1.0 Purpose
The purpose of Volume 2, Plant Inspection Procedures, is to provide inspection personnel of
the Kuwait Oil Company (KOC) with procedures to properly and adequately perform
inspection of KOC facilities. These inspections will form part of the KOC Mechanical
Integrity Program.
The program will entail prevention, detection, and mitigation activities that will result in
improved safety and reliability and a reduction in the number of incidents (i.e., loss of
containment and commercial losses) as well as enhancing life extension decisions for
equipment and facilities. In other words, these inspection procedures will be the process that
the KOC uses to detect, assess and mitigate risks in order to reduce the probability and
consequences of incidents.
Inspection is a critical component of successful operation and maintenance of oilfield

production facilities. Improper and inadequate inspection can increase capital and/or
operating expenses and can result in equipment failures due to several threats. The threat of
system operational upsets can be minimized by prudent and proactive inspection using
qualified and experienced personnel. However, it is a primary objective of the KOC to
eliminate these threats by their prompt identification through effective inspection followed by
immediately taking corrective actions to prevent their recurrence. This objective is portrayed
in Figure 1.0, Corrective and Preventive Action.
Prevent
Occurrence
Preventive
Action
Potential Prevent
Nonconformity Reoccurrence
Corrective
Action
Detected
Nonconformity
Figure 1.0
Correction and Preventive Action
2.0 Scope

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(a) These procedures will cover the inspection of specified KOC pipeline and oil
and gas production facilities by systems, such as piping systems, pressure
vessels including boilers, heaters, and heat exchangers, storage tanks, and
safety relief and flare systems. Each system will have specific procedures,
which will be addressed in Procedure Numbers PLTIP-002-BPV to PLTIP-
008-FLR of Volume 2, as listed in Paragraph 7.2 below. This revision of
Volume 2 contains a total of 14 parts or specific procedures.
(b) Also included are offshore facilities and offsite equipment and wastewater
treatment plants associated with the KOC. Procedures for each of these
systems will be addressed in Procedures PLTIP-009-WAT to PLTIP-011-OEQ
of this volume, as indicated in Paragraph 7.2.
(c) These procedures will be supplemented with additional procedures relating to
the repair, modification and rehabilitation of existing facilities, inspection
reporting and equipment certification as well as the storage, retrieval and
updating of the associated inspection reports. PLTIP-012-RHB to PLTIP-014-
DOC also listed in Paragraph 7.2 will address these aspects.
(d) The scope of work addresses in-service equipment and facilities that have been
subjected to various operating environments and conditions. Therefore, the in-
service inspection codes of practice such as the American Petroleum Institute
(API) and The National Board Inspection Code have been adapted to KOC
inspection requirements. Specific references will be listed in the relevant
referenced documentation section of each procedure (see Paragraphs 7.1 and
7.3).
(e) The primary focus of these procedures will be to inspect internally and
externally for the mechanical, structural and physical integrity of the KOC
facilities and equipment (i.e., to detect defects). These inspection procedures
will focus on the following imperfections:
i) corrosion
ii) cracks (notably HIC or SCC)
iii) deformation
iv) deterioration, and
v) mechanical damage
(f) Equipment inspection ultimately will achieve the strategic, long-term goal of
the effective management of mechanical integrity of KOC facilities.
Achieving this goal will also ensure the following operational and business
advantages:
i. All KOC equipment is in optimum operating condition (i.e., operate safely

and reliably) with a focus on maintenance and prevention (not repair) as
shown in Figure 1.0.
ii. The effective use of maintenance resources is achieved by standard
procedures and practices.

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iii. Effective maintenance planning and scheduling is achieved with standard

maintenance practices (i.e., maximum production capacity).
iv. The procedures and practices will ensure that each task is written out so
that any qualified personnel properly complete each task efficiently (i.e., in
the minimum required time and effort).
v. The procedures specify the proper training and skills necessary for
personnel to effectively complete his assigned tasks and strive for
continuous improvement
(g) These procedures are structured to be both prescriptive- and performance-based

inspection processes although more emphasis will be placed on the prescriptive
process. Inspection intervals will be based on the traditional time based or “calendar-
based” interval inspection concept as opposed to Risk Based Inspection (RBI). RBI
is evolving rapidly as more operating and maintenance history becomes available.
Inspection will then be driven by the equipment condition when a better
understanding of the type and rate of deterioration is better understood.
2.1 Terminology and Definitions

2.1.1 API Authorized Inspector: An employee of an authorized inspection agency who is
qualified and certified to perform inspection under the auspices of the API code.
2.1.2 Corrosion: Degradation of steel by chemical or electrochemical dissolution that
occurs as a result of the interaction of the steel with its environment. Includes
external, internal, galvanic, microbial or rust corrosion).
2.1.3 Cracking: Mechanical splitting into parts.
2.1.4 Defects: An imperfection of a type and magnitude exceeding acceptance criteria.
2.1.5 Deformation: A permanent change or discontinuity in the original geometric shape of
a component (e.g., a distortion or deflection including settling, bulging,
misalignment).
2.1.6 Deterioration: The physical “wear and tear” of a component or facility due to ageing,
usage and exposure to operating or natural environments. (e.g., blistering, peeling,
erosion, leakage, spalling such as for concrete).
2.1.7 Hydrogen Induced Cracking (HIC): A form of hydrogen induced damage
consisting of cracking of the metal.
2.1.8 KOC Inspector: An employee of the KOC who is authorized by the KOC Inspection
and Corrosion Team to perform inspection or supervision of inspection of agency or
organization personnel of KOC assets.
2.1.9 Imperfection: A material discontinuity or irregularity that is detectable by inspection
in accordance with the requirements of these procedures.
2.1.10 Inspection Organization or Agency Inspector: Inspectors of an organization or
agency contracted or hired by the KOC to perform inspection duties on KOC assets.

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Inspection agency or organization personnel (inspectors) will typically be under the

direct supervision of the KOC Inspector.
2.1.11 Liquid (Dye) Penetrant Inspection: A non-destructive inspection process used to
find discontinuities that are open to the surface of a solid (non-porous material).
2.1.12 Management of Change: A process that systematically recognizes and
communicates to the necessary personnel changes of a technical, physical, procedural
or organization nature that can impact the system’s mechanical integrity.
2.1.13 Mechanical Damage: A type of damage to equipment or a facility caused by the
application of an external force (e.g., impact, creep, fatigue, thermal shock or cyclic
loadings).
2.1.14 Mitigation: The limitation or reduction of the probability of occurrence or expected
consequences for a particular event. Some examples of mitigation include applying
cathodic protection, painting (repainting), or installing liner material
2.1.15 Nondestructive Testing: Examination of pipeline system materials using
radiographic, ultrasonic, or other methods that do not involve disturbance stressing, or
breaking of the materials to reveal imperfections.
2.1.16 Offshore Pipeline: A pipeline that is installed seaward of the ordinary high water
mark or from a similar point on the shoreline of major inland waters.
2.1.17 Performance-Based Inspection: An inspection process that utilizes risk management
principles and risk assessment to determine prevention, detection, and mitigation
actions and their timing.
2.1.18 Permit: A formal written agreement issued by KOC Operations to the KOC Inspector
authorizing inspection and related work, including repairs, modifications, and./or
replacements, for work activities on KOC assets.
2.1.19 Prescriptive-Based Inspection: An inspection process that follows preset conditions
that result in fixed inspection and mitigation activities and timelines.
2.1.20 Radiographic Inspection: A non-destructive method of inspecting welds that uses a
radiation source and radiographic film.
2.1.21 Repair: The work necessary to restore a component or components to a condition
suitable for safe operation at the design conditions. A repair can be the addition or
replacement of pressure or non-pressure parts that do not change the rating of the
vessel. Where such repair(s) changes the design temperature or pressure, the
requirements for re-rating shall be satisfied.
2.1.22 Re-Rating: A change in either the temperature ratings or the maximum allowable
working pressure rating of a component or both..
2.1.23 Risk Based Inspection (RBI): A process in which the evaluator assigns a “criticality
rating” to a limited series of maintenance inspection conditions, in order to compare
the piece of equipment to a larger database of similar information with the specific
intent to extend the interval between inspections.
2.1.24 Stress Corrosion Cracking (SCC); A form of environmental attack of the metal
involving an interaction of a local corrosive environment and tensile stresses in the
metal resulting in formation and growth of cracks.

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2.1.25 Ultrasonic Inspection (UT): Examination using high frequency sound (non
destructive) to determine wall thickness and to detect the presence of defects.
2.1.26 Visual Inspection: The process of inspection by visual examination with the purpose
of observation to detect and identify any indications for recording, further analysis or
testing, subsequent actions (mitigation/repair) and/or final acceptance or rejection
(disposition).
Each of the other procedures in this volume will also contain a list of terminology and
definitions that are deemed necessary to assist users of that procedure.
3.0 Responsibilities
The relationship of the inspection responsibilities within the KOC organization is shown in
Figure A.1, Inspection & Corrosion Team Reporting Structure (Simplified) organization
chart. The make-up of the Inspection and Corrosion Teams in the KOC organization is shown
on Figure A.2, Inspection and Corrosion (I&C) Team (NW) Organization Chart and Figure
A.3, Inspection and Corrosion (I&C) Team (SE) Organization Chart.
3.1 KOC General

KOC shall be committed to the development and implementation of the inspection
management program. KOC will demonstrate this commitment by:
a) Establishing and providing the inspection management policy
b) Ensuring that the inspection objectives are established and met at relevant functions
and levels within the KOC organization
c) Ensuring the availability of resources, particularly trained, qualified (certified) and

competent inspection personnel including those from contracted third party inspection
organizations, and
d) Ensuring, by communication and awareness, that all inspection personnel understand

the importance of their roles and activities and how they align with KOC corporate
visions and objectives.
3.2 KOC Inspection and Corrosion Team

The Inspection and Corrosion Team shall be responsible for:
a) Establishing the processes needed for the inspection management system and their
application including sequence and interaction throughout the KOC
b) Implementing, reviewing and maintaining the inspection management system
c) Documenting the processes to ensure their operation and control in the inspection
management system

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d) Determining and implementing corrective actions necessary to achieve planned

results of these processes including ensuring that all jurisdictional requirements are
continuously met, and
e) Continually improving the effectiveness of the inspection management system in
accordance with industry leading standards and practices.
3.3 KOC Senior Engineer

The KOC senior engineer shall be responsible for:
a) Development of the testing and inspection scope of work.
b) Providing technical support including engineering review, analysis, and evaluations
and approvals for testing methods and parameters in addition to or outside of those
currently specified by these procedures.
c) Engineering acceptance, approval, and filing of testing and inspection documents.
3.4 KOC Inspectors

KOC inspectors shall be responsible for:
a) Performing the inspection work in accordance with KOC requirements
b) Determining and ensuring that the requirements of applicable standards, regulations,

codes, etc. are met, and
c) Ensuring that the work of outside inspection organizations and resources conform to
KOC requirements.
3.5 Outside Inspection Organization
Outside or external inspection organizations hired by the KOC shall be responsible for:
a) Obtaining and maintaining inspection competency including certification, where
necessary for performing the inspection work in accordance with KOC requirements
b) Determining and ensuring that the requirements of applicable standards, regulations,

codes, etc. are met, and
c) Maintaining direct involvement in the inspection activities (when engaged by KOC)
to be able to identify any flaws in the process or facility and making recommendations
for corrective actions in the inspection report.
4.0 Training and Qualifications

Training and Qualification for each of the inspection activities are duly noted in each
procedure. Since inspection is performed on in-service equipment and the procedures follow
the in-service inspection codes of practice such as the American Petroleum Institute (API),
the training requirements are structured to follow the API format as well. This structure is
based on the following format:

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a) Examination
b) Qualification
c) Certification
Personnel will be trained and qualified on the basis of appropriate education, training, skills
and experience required for performing a specific inspection assignment.
5.0 Procedures
5.1 Objectives
The basic objectives of these procedures are:
(a) To enable Inspection and Corrosion (I&C) Teams to qualify for ISO certification in
accordance with ISO 9001.
(b) To provide comprehensive steps for inspection of KOC facilities in a clear and simple
format that can be readily followed by both experienced and inexperienced (junior)
engineers.
(c) To address all pertinent safety issues that need to be adhered to by all personnel
performing inspection of the facilities, especially those carrying toxic, hazardous
and/or hydrocarbon products.
5.2 Safety Precautions

All activities performed in accordance with these procedures shall follow industry leading
safe work practices as referenced in Paragraph 7.0, Referenced Documentation.
The KOC is committed to prevent unacceptable risks to employees, the public and
environment and prevent loss by ensuring safe work permits are used while performing
controlled work. Safety procedures shall apply to all employees and contractors at KOC.
A safe work permit must be used whenever inspection work is to be performed on KOC
assets.
5.2.1 Safety Process Steps for Safe Work Permit(s)
The following steps shall be performed during a safe work permit project/procedure.
Step 1:Identify and designate the safety site representative (permit issuer).
Step 2: Identify the Permitted Work. This shall be determined by holding a pre-job meeting,
conducting a hazard assessment, and determining the safe work permit(s) to be issued.
Step 3: Prepare the Work Permit(s). This step will determine the time required for
completion of the work, state the valid dates of the permit and record the names of
individuals to whom the permit will be issued

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Step 4: Issue the Permit(s). Issuance of the permit will indicate that all tests and preparations
have been completed and the work plan has been communicated to all site personnel prior to
the inspection work. KOC Operations in conjunction with HS&E will issue the work permit.
Step 5: Control Records. The safe work permit shall be issued to the permit receiver (the
KOC Inspector) who will retain a copy at the worksite(s).
Step 6: Monitor Tasks and Activities. This step empowers all employees to stop work
immediately in the event a safety hazard presents itself or work conditions specified in the
permit are changed (e.g., a leak or equipment failure). Where necessary, the situation shall be
evaluated to confirm if current procedures suit the conditions; if not, the procedures shall be
modified and a new safe work permit issued.
5.2.2 Other Safety Requirements

KOC safety regulations including leading industry standards and practices shall be followed
for all work activities. The appropriate safety steps that shall be satisfied shall be dependent
upon the results of the hazards assessment that shall be performed in advance of all work
activities. Safety procedures shall include but not be limited to the following:
(a) Securing a work permit, which identifies the safety site representative.
(b) Ensuring the availability of appropriate safety equipment (safety glasses, suitable
masks and associated breathing apparatus). Note that most of the KOC hydrocarbon
streams contain varying amounts of H2S gas, which require that extreme precautions
be taken at all times. Iron sulphide scales (known as pyrophoric scale) may be found
in certain KOC vessels handling sour hydrocarbons. These scales have been known to
cause fires in the past.
(c) Establishing a “buddy system” whereby KOC or contractor personnel are nearby with
radio communication to provide and/or obtain immediate assistance in the event of an
emergency.
(d) Ensuring that the systems being worked on are safely depressurized or emptied
(completely drained, flushed, cleaned and gas freed).
(e) Ensuring that safe site conditions are created such as excavation of proper trenches
(adequate shoring/sloping), scaffolds erected, etc.
5.3 Inspection Program

These procedures provide the inspection scope of work required for each facility and system
within the KOC plant facilities and will include the inspection techniques and documentation
formats that shall be followed.
These procedures form the Perform Inspection activity of the Mechanical Integrity
Management Plan. This relationship is shown in Figure B.1, Mechanical Integrity
Management Plan Process below. The relationship of the Mechanical Integrity Management
Plan Process within an overall Integrity Management Program is shown in ASME B31.8S –

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2001 (Supplement to ASME B31.8), Managing System Integrity of Gas Pipelines. This plan
process is equally applicable to liquids pipeline systems and has been customized to suit the
KOC organization.
5.3.1 Planning
The planning work leading up to and following inspection is performed by others, namely the
Inspection and Corrosion Team, who will:
a) Categorize and prioritize all the systems for inspection
b) Plan and scope out the system-wide inspection program
c) Perform the engineering evaluation (assessment) of the data gathered from inspection
d) Apply the findings of the evaluation (assessment) to other equipment in similar or
different systems and activities (e.g., design of new facilities).
5.3.2 Scope of Inspection Procedures

These procedures will discuss:
i) WHY the inspection is being done
ii) WHAT will be inspected and WHAT you are inspecting for
iii) WHO is responsible and for what actions and WHAT their roles are
iv) WHAT knowledge and skills are required to perform inspection
v) HOW TO perform the inspection
vi) WHAT information and data needs to be obtained and recorded
vii) WHAT codes and standards are relevant, and
viii) WHAT additional information is required or to be provided
ix) WHEN the inspections will be performed
The primary focus of these procedures is to state the “HOW TO” for performing inspection
of KOC equipment and facilities in accordance with leading industry standards and practices.
5.3.3 Focus of API Inspection Procedures

The procedures of API RP 579 as discussed in Volume 9, Procedures for Determining
Remaining Life of Equipment, are applied to the following types of flaws and material
conditions:
1) Brittle Fracture
2) General Metal Loss
3) Local Metal Loss
4) Pitting Corrosion
5) Blisters and Laminations
6) Weld Misalignment and Shell Distortions
7) Crack-Like Flaws
8) Components Operating in the Creep Regime

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9) Fire Damage
5.3.4 Focus of KOC Inspection Procedures

For the purposes of the assessment procedures of this Volume 4, the following general flaw
categories will be adopted for KOC inspection:
1) Corrosion: will include internal, external, MIC (microbial induced corrosion),
galvanic, and rust
2) Cracks: will include SCC (stress corrosion cracking), HIC`(hydrogen induced
cracking), SSC (side step cracking), and hairline cracks
3) Deformations: will include bulging, buckling, misalignment, settling, deflection, and
distortion
4) Deterioration: will include blistering, peeling, leakage, spalling, laminations, cracks
(visible to the human eye such as in concrete), and
5) Mechanical Damage: will include fire damage, creep, impact, malfunctions, fatigue,
thermal shock, and cyclic loadings.
These above flaw types have been categorized to suit KOC inspectors in their flaw
categorizations, as opposed to using terminology applied in materials engineering and
complex failure analysis. Consequently, these terms will be shown in the appropriate flow
charts of the relevant inspection procedures in this volume.
5.3.5 Inspection Tools and Processes

Inspection methods that will be employed on KOC plants will include:
2.1.1 Visual Inspection
2.1.2 Magnetic Particle Inspection
2.1.3 Liquid (Dye) Penetrant Inspection
2.1.4 Radiography
2.1.5 Ultrasonic Testing
See Paragraph 2.1, Terminology and Definitions, for a description of these inspection
processes.
These processes will be supplemented by other processes that KOC inspectors may use to
assist them in their duties. These processes are discussed in other KOC procedures as listed
in Paragraph 7.2, Related Standards and will include obtaining reports from Operations
personnel, taking measurements, fitness-for-service assessments, welding and pressure
testing. Combined with analyses and managed maintenance, total integrity assurance will be
achieved.
5.3.6 Types of Inspection

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The integrity assurance of KOC operational plants, facilities and equipment will be
confirmed by inspection until the next scheduled inspection. Operational plants and facilities
in the KOC will have the following types of inspection performed on them:
(a) On-Stream Inspection: On- stream inspection is performed externally such that the
system is not entered for internal inspection (usually because it remains in operation
while inspection is performed). This type of inspection will be the most routine type
of inspection performed, as it is non-intrusive. However, it is still considered to be
very effective as all major components of the plant are examined to provide a sound
assessment until the next scheduled inspection. Lists of the major components that
shall be inspected as part of on-stream inspection for the different types of systems
found in the KOC are tabulated in Appendix E.
(b) Planned Inspection (Preventive Maintenance Surveys): This type of inspection

will be time-based, cycle-based or condition-based and will usually involve internal
inspection. This type of inspection may also be driven by results obtained from
previous inspections including assessments obtained from the processes involved in
Procedures for Determining Remaining Life of Equipment in Volume 10 of these
procedures (see Paragraph 7.2, Related Standards).
(c) Mothballing/De-Mothballing: This term is given to inspections that will be

performed on plants or facilities, which are planned to be removed from service and
maintained for later return to service; conversely de-mothballing is the type of
inspection that will be performed on plant planned to be returned to service after
having been out of service for a finite time. KOC Mothballing/De-Mothballing
standards, available from the I & C Team, provide details for inspection.
5.3.7 Inspection Cycles

The cycle of planned inspections for the KOC vary by geography of the system, mainly
because of the product quality in each region. Consequently, this gives rise to adopting a
different inspection cycle for the system as described in the following.
(a) North Kuwait: This part of the system typically encounters sweet service duties and
have the following inspection cycles:
i. Minor Surveys- every 2 years
ii. Intermediate Surveys- every 4 years
iii. Major Surveys- every 8 years for Gathering Centers (GC) and every 4 years
for Booster Stations (BS).
(b) South, East & West Kuwait. These parts of the operating zones typically encounters
sour service duties and will require the following inspection cycles:
i. Minor Surveys- every 2 years
ii. Major Surveys- every 4 years for both GC’s and BS’s.
6.0 Data Requirements

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There are none at this time.
7.0 Referenced Documentation

(a) References
7.1.1 T. G. Clevenger, “Organizing A Vessel, Tank and Piping Inspection Program”,
National Board Classic Series, National Board BULLETIN, July 1991.
7.1.2 A. S. Krisher, “Plant Integrity Programs”, National Board Classic Series, National
Board BULLETIN, January 1988.
(b) Related Standards

Procedure Number Volume No.
PLTIP Volume 2- Plant Inspection Procedures
PLTIP-001-GEN General
PLTIP-002-BPV Pressure Vessels (all categories)
PLTIP-003-TNK Storage Tanks (all categories)
PLTIP-004-HXR Heat Exchanger Equipment (all categories)
PLTIP-005-HTR Heaters
PLTIP-006-TUB Direct Fire Water Tube Boilers
PLTIP-007-RLF Safety and Safety Relief Systems
PLTIP-008-FLR Flare Systems
PLTIP-009-WAT Waste Water Treatment Plant
PLTIP-010-OFF Offshore Facilities
PLTIP-011-OEQ Offsite Facilities
PLTIP-O12-RHB Repair, Modification and Rehabilitation of Existing Facilities
PLTIP-013-EQC Procedure for Inspection Report and Equipment Certification
PLTIP-014-DOC Procedure for Electronic Storing, Retrieving & Updating of Reports
INVTY Volume 3 - KOC Facilities Inventory
INVTY-001-FAC
PIPIP Volume 4 – Pipelines and Piping Inspection Procedures
PIPIP-001-GEN General
PIPIP-002-ILI Procedures for Intelligent Pigging of Pipelines
PIPIP-003-HYT Procedures for Hydrostatic Testing
PIPIP-004-DAP Procedures for Direct Assessment of Pipelines

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PIPIP-005-PLT Procedures for Inspection of In-Plant Piping

PIPIP-006-TUB Procedures for Tubular Inspection
PIPIP-007-RPR Procedures for Repairs and Modification of Pipelines and Piping
PIPIP-008-RHB Procedures for Rehabilitation of Pipelines
NDTIP Volume 5 – Non-Destructive Testing (NDT) Procedures
NDTIP-001-GEN General
NDTIP-002-RAD Radiographic Testing Procedure
NDTIP-003-UTP Ultrasonic Testing (UT) Procedure
NDTIP-004-MAN Manual Ultrasonic Testing for SCC and HIC
NDTIP-005-AUT Automatic Ultrasonic Testing for SSC and HIC
NDTIP-006-MPI Magnetic Particle Inspection (MPI) Procedure
NDTIP-007-LPT Liquid Penetrant Testing (LPT) Procedure
NDTIP-008-EDY Eddy Current Examination Procedure
NDTIP-009-MLL Metallographic Examination Procedures of Materials
NDTIP-010-HRD Hardness Testing Procedure
NDTIP-011-PMI Positive Material Identification (PMI)
NDTIP-012-V&D Visual and Dimensional Inspection Procedures
WLDQT Volume 6 – Welding, Welding Procedures, Qualifications and Testing
WLDQT-001-GEN Welding, General Requirements and Inspection
WLDQT-002-PRO Welding Procedure Review and Approval
WLDQT-003-PER Welder Performance Review and Approval
WLDQT-004-MTL Weld ability of Common Materials
WLDQT-005-CRA Welding of Corrosion Resistant Alloys (CRAs)
WLDQT-006-PIE Welding of Pipelines and Piping
WLDQT-007-BPV Welding of Pressure Vessels
WLDQT-008-ATL Weld Defect Atlas
WLDQT-009-TMY Welding and NDT Terminology
WLDQT-010-PWT Post Weld Heat Treatment Procedure
PTEST Volume 7 – Pressure Testing
PTEST-001-GEN General
PTEST-002-HXR Testing of Pressure Vessels and Heat Exchanger Unit
PTEST-003-TNK Pressure Testing of Storage Tanks

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PTEST-004-PIE Pressure Testing of Pipelines

PTEST-005-RLF Valves and Safety Relief Valve Testing
PTEST-006-PLT Pressure Testing of Plant Piping
LFAPL Volume 8 – Lifting Appliances
LFAPL-001-GEN General
LFAPL-002-MOB Inspection, Testing and Certification of Mobile Cranes
LFAPL-003-OHC Inspection, Testing and Certification of Overhead Cranes
LFAPL-004-OFF Inspection, Testing and Certification of Offshore Fixed Appliances
LFAPL-005-OLA Inspection, Testing and Certification of Other Lifting Appliances
LFAPL-006-OPR Training and Certification of Lifting Appliances Operators
CORPP Volume 9 – Corrosion and Corrosion Protection Procedures
CORPP-001-CTG Coatings Testing Procedures
CORPP-002-MTL Materials Selection Procedures
CORPP-003-INH Procedures for Corrosion Inhibition and Monitoring
CORPP-004-CPM Procedures for Cathodic Protection Maintenance
RLIFE Volume 10 – Procedures for Determining Remaining Life of Equipment
RLIFE-001-GEN General Approach for Remaining Life and Fitness-for-Service Assessment
Procedures for Remaining Life and Fitness-for-Service Assessment for
RLIFE-002-GCC Critical Components in Gathering Centers
Procedures for Remaining Life and Fitness-for-Service Assessment for
RLIFE-003-BSC Critical Components in Booster Station
Represents the current applicable inspection procedure

Represents a directly related inspection procedure
7.3 Industry Standards

7.3.1 API RP 580, Risk-Based Inspection, API Recommended Practice 580, First Edition,
American Petroleum Institute, Washington, D.C., Draft #5, January 2001.
7.3.2 API RP 579, Fitness-For-Service, API Recommended Practice 579, First Edition,
American Petroleum Institute, Washington, D.C., January 2000.
7.3.3 API RP 578, Material Verification Program for New and Existing Alloy Piping
Systems, 2nd Edition, American Petroleum Institute, Washington, D.C., December
2000.
7.3.4 API RP 576 Inspection of Pressure Relieving Devices, Second Edition, American
Petroleum Institute, Washington, D.C., December 2000.

TECHNOLOGIES
GENERAL
7.3.5 API RP 575, Guidelines and Methods for Inspection of Existing Atmospheric & Low
Pressure Storage Tanks, American Petroleum Institute, Washington, D.C., 1st Edition,
November 1995.
7.3.6 API RP 574, Inspection of Piping System Components, 2nd Edition, American
Petroleum Institute, Washington, D.C., June 1998
7.3.7 API RP 573, Inspection of Fired Boilers and Heaters, First Edition, American
Petroleum Institute, Washington, D.C., October 1991.
7.3.8 API RP 572, Inspection of Pressure Vessels, Heat Exchangers, Condensers and
Coolers, Second Edition, American Petroleum Institute, Washington, D.C., February
2001.
7.3.9 API 570, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-
Service Piping Systems, Second Edition, American Petroleum Institute, Washington,
D.C., June 1998, Addenda 1 and 2.
7.3.10 API 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair
And Alteration, Eighth Edition, American Petroleum Institute, Washington, D.C.,
1997, with Addenda 1, 2, and 3.
7.3.11 API 653, Tank Inspection, Repair, Alteration, and Reconstruction, Third Edition,
Revision 1, American Petroleum Institute, Washington, D.C., December 2001.
7.3.12 API STD 650, Welded Steel Tanks for Oil Storage, Tenth Edition, American
Petroleum Institute, Washington, D.C., 1998, with Addenda 1 and 3.
7.3.13 API STD 620, Design and Construction of Large, Welded, Low-Pressure Storage
Tanks, Tenth Edition, American Petroleum Institute, Washington, D.C., February
2002.
7.3.14 ASME B31.8S – 2001 (Supplement to ASME B31.8), Managing System Integrity of
Gas Pipelines, ASME Code for Pressure Piping, B31, an American National Standard.
7.3.15 ASME B.31G-1991 (Revision of ANSI/ASME B31G-1994), Manual for Determining
the Remaining Strength of Corroded Pipelines, ASME Code for Pressure Piping, B31,
an American National Standard.
7.3.16 ASME Boiler and Pressure Vessel Code, Section I: Power Boilers, ASME
International, New York, 2001.
7.3.17 ASME Boiler and Pressure Vessel Code, Section II: Nondestructive Examination,
ASME International, New York, 2001.
7.3.18 ASME Boiler and Pressure Vessel Code, Section V: Materials – Part D – Properties,
7.3.19 ASME Boiler and Pressure Vessel Code, Section VIII: Pressure Vessels – Division 1,
7.3.20 ASME Boiler and Pressure Vessel Code, Section IX: Welding and Brazing
Qualifications, ASME International, New York, 2001.
7.3.21 ASME Boiler and Pressure Vessel Code, Section VIII: Pressure Vessels – Division 2
– Alternative Rules, ASME International, New York, 2001.
7.3.22 ASME B31.1: Power Piping, ASME International, New York, 2001.

TECHNOLOGIES
GENERAL
7.3.23 ASME B31.3: Process Piping, ASME International, New York, 2002.
7.3.24 The ISO 9000:2000 Essentials, Plus 9001, 3rd Edition, A Practical Handbook for
Implementing the ISO Standards, Canadian Standards Association, 2001.
8.0 Appendices
Appendix A – Figure A.1, Inspection & Corrosion Team Reporting Structure (Simplified)
Figure A.2, Inspection and Corrosion (I&C) Team (NW) Organization Chart
Figure A.3, Inspection and Corrosion (I&C) Team (SE) Organization Chart
Appendix B – Figure B.1, KOC Mechanical Integrity Management Plan Process
Appendix C – Figure C.1, KOC Equipment/Facility Inspection Flow Chart
Appendix D – Figure D.1, Inspection Assessment Flow Chart
Appendix F – Table F.1, On-Stream Inspection Checklist – Plant Components

TECHNOLOGIES
GENERAL
APPENDIX A
FIGURE A.1, INSPECTION & CORROSION TEAM REPORTING STRUCTURE
(SIMPLIFIED)
ORGANIZATION CHART
ORGANIZATION CHART

TECHNOLOGIES
GENERAL
APPENDIX A
Figure A.1, Inspection and Corrosion Team Reporting Structure (Simplified)
Inspection and Corrosion (I&C)

Team
Team Leader
Specialist
Leaders/
Supervisors
Senior Engineers

Engineers
UD Engineers
Senior Technicians
Inspectors Technicians
Functional
Administrative
Reporting
Contractors Outside Inspection
Organization/Contractor

TECHNOLOGIES
VOLUME 4 - PIPING AND PIPELINE INSPECTION
GENERAL
PROCEDURE NUMBER: PIPIP-001-GEN
APPENDIX A
Figure A.2, Inspection and Corrosion (I&C) Team (NW) Organization Chart
TEAM LEADER I&C (NW)
Secretary Snr. Engr.

Admn. & Contracts
Snr. Engr. I&C Snr. Engr. I&C Snr. Engr. I&C Snr. Engr. I&C Snr. Engr. I&C (ICMPII)
(N) (Proj.) (W) (ICMPI)
I&C Engrs. I&C Engrs. I&C Engrs. I&C Engrs. I&C Engrs.
UD Engrs. UD Engns. UD Engrs.
Snr. I&C
Techn. Snr. I&C Snr. I&C
Techn. Techn.
I&C Techn.

GENERAL
Figure A.3, Inspection and Corrosion (I&C) Team (SE) Organization Chart
TEAM LEADER I&C

(SE)
Tech Asst. Secretary Specialist
Snr. Engr. I&C Snr. Engr. I&C Snr. Engr. I&C Snr. Engr. I&C
(S) (Proj.) (GW) (E)
I&C Engrs. I&C Engrs.

I&C Engrs. I&C Engrs.
UD Engrs. UD Engrs. UD Engrs.

UD Engrs.
Snr. I&C Snr. I&C

Techns. Techns.
I&C Techn. I&C Techn.

I&C Techn.
& Asst.

KUWAIT OIL COMPANY (KO
INSPECTION AND CORROSION PROCEDURE MANUAL
GENERAL
APPENDIX B
FIGURE B.1, KOC MECHANICAL INTEGRITY MANAGEMENT PLAN PROCESS

GENERAL
APPENDIX B
Figure B.1, KOC Mechanical Integrity Management Plan Process
Data Gathering, Review &

Integration
Threat
Evaluation
Criterion & Risk Assessment
Yes
All Threats
Evaluated
Perform Inspection
(See Figure C.1)
Yes
Is
Mitigation (See Figure D.1)
Necessary?
No
Determine Re- Update Records Manage Change

inspection Interval
Note: This figure is based on Integrity Management Plan Process Flow Diagram in ASME B31.8S-2001

GENERAL
APPENDIX C
FIGURE C.1, KOC EQUIPMENT/FACILITY INSPECTION FLOW CHART

GENERAL
APPENDIX C
Figure C.1, KOC Equipment/Facility Inspection Flow Chart
Initiate
Inspection
Select KOC Inspection

and/or Inspection Agency
Select KOC Inspection

and/or Inspection Agency
Establish and Review Roles and

Responsibilities
Establish and Review

Scope of Work
Assemble and Review

Equipment
History and Records
Establish Inspection Plan
Establish Inspection Safety

Requirements
Assemble and Check Inspection Tools
Perform Inspection
Assess Inspection Findings See Figure

D.1

GENERAL
APPENDIX D
FIGURE D.1, INSPECTION ASSESSMENT FLOW CHART

GENERAL
APPENDIX D
Figure D.1, Inspection Assessment Flow Chart
Inspection
Assessment
Is Yes
Mitigation/
Repair
Necessary?
Mitigate or Delay Repair

Repair Now
No
No
Is
Replace Repair
Equipment Complete?
Return to
Service

GENERAL
APPENDIX F
TABLE F.1, ON STREAM-INSPECTION CHECKLIST – PLANT COMPONENTS

GENERAL
Table F.1, On-Stream Inspection Checklist – Plant Components
Facility/Location: Inspected by:
Inspection Date:
Signature
SYSTEMS/COMPONENTS INSPECTION COMMENTS
A PRESSURE VESSEL ACCCEPTABLE

1 Structures YES NO
a Ladders
b Platforms
c Stairways
d Walkways
2 Foundation and Supports
a Cracking
b Settlement
c Spalling
d Sulfate Attack
3 Anchor Bolts
a Corrosion
b Over Tightening
c Cracks
d Distortion
4 Nozzles
a Distortion/Cracking
b Flange Leaks
c Leaks on nozzle to shell joints
5 Earthing Connection
a Earthing Points
b Earth Connections
c Potential Equalization Bus Bar
d Conductors
6 Insulation Condition
a Insulation Material
b Lagging/Jacket
c Condensation
d Corrosion under the insulation
7 External Painting Condition
a Corrosion
b Leaks
c Buckles
d Bulges
e Other Defects in shell
f Weld Joints Condition
8 Auxiliary Equipment Condition

GENERAL
a Safety /Relief Valves

b Level Gauge
c Pressure Gauge
d Temperature Gauge
9 Performance (Operating)
a Temperature
b Pressure
c Relief Valve Set Up Pressure
B SHELL & TUBE HEAT
EXCHANGERS
1 Structures
a Supports/supporting structures
b Foundations Settlement
Conditions
c Anchor Bolts
d Other Structures
2 Nozzles
b General Condition
c Flange leaks
d Any other Leak
A Earthing Points
B Earth Connections
C Potential Equalization Bus Bar
D Conductors
4 Auxiliary Equipment
a Safety valves
b Pressure Gauge
c Temperature Gauge
5 External Paint Condition
a Corrosion
b Leaks
c Buckles
d Bulges
6 External Metal Surfaces
a Corrosion
b Distortion
c Stress Cracking
d Mechanical Damage
7 Connected Piping
a Channel Box Joint
b Tubesheet to shell joint
8 Leakage at Connections
a Vibration
b Deformation of Piping
c Weld Defects

GENERAL
9 Operating Performance
a Temperature
b Pressure
c Pressure Drop
d Heat Transfer Rate
C PIPING
1 Leaks at Joints
a Flanged joints
b Threaded joints
c Welded joints
d Gaskets
2 External Corrosion
a Coating
b Wall thickness
c Cathodic protection
3 Leaks on Pipe (clamps)
a Steel packing
b Thrust washers
c Point cones
4 Vibrations
a Supports
b Hangers
c Joints
d Alignment
5 Insulation
a Insulation material
b Lagging
c Condensation
6 Pipe Supports & Brackets
a Structural steel
b Concrete piers
c Bolts/welds
7 Condition of Valves
a Casing
b Seat and disk
c Stem and bushing
d Stuffing box
D PUMPS/COMPRESSORS
1 External Visible Defects

a Corrosion
b Dents
c Deformation
2 Unusual Noise
a Clearance between impeller and
wear ring

GENERAL
b Bearing
3 Vibration
a Shaft coupling
b Compressor drive
c Connections
4 Pressure & Temperature of
Lube Oil & Cooling Water
a Gauges
b Heaters
c Fans
5 Gland Packing/Mechanical Seal
Leaks
a Corrosion
b Defects
c Deformation
6 Pressure Gauges
a Pressure settings within operating
limits
b Pressure relief device
7 Temperature Gauges
a Temperature setting within
operating limit
8 Performance
a Power supply
b Safety devices
c Shock control devices
9 Condition of Standby
Equipment
a Mechanical damage
b Welded joints condition
c Corrosion
E HEATERS
1 External Visible Condition
a Dents
b Deformation
c Corrosion
2 Insulation Condition
a Insulating material
b Steel straps
c Lagging
3 Overheating Bulging
a Duct connection
b Sealing strip
c Casing
4 Foundation
a Cracks

GENERAL
B Spalling
c sulfate attack
d settlement
5 Flame Pattern
a Flame color
b Flame position within heat
exchanger opening
a Inlet/outlet connections
b Hinges
7 Structures
a Corrosion
b Elements
c Cracks
8 Performance (Operating)
a Gas pressure
b Operating limits functioning
F AIR COOLED EXCHANGERS
1 Structures
a Supports/Supporting Structures
b Foundations Settlement
Conditions
c Anchor Bolts
d Other Structures
2 Nozzles
b General Condition
c Flange Leaks
d Any Other Leak
a Earthing Points
b Earth Connections
c Potential Equalization Bus bar
d Conductors
4 Auxiliary Equipment
a Safety Valves
B Pressure Gauge
c Temperature gauge
5 External Paint Condition
a Corrosion
b Leaks
c Buckles
d Bulges
6 External Metal Surfaces
a Corrosion
b Stress cracking
c Mechanical damage
7 Tube Leak

GENERAL
a Sagging
b Bulging
c Cracks/splitting
8 Connected Piping
a Welded connections
b Tubesheet to shell joint
c Channel box joint
F AIR COOLED EXCHANGERS
9 Conditions of
a Motor
b Fan Blades
c Fan V-Belt Assembly
d Condenser
10 Operating Performance
a Air flow Control
b Air Recirculation
c Safety – Leaks in unit

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VOLUME 2 – PLANT INSPECTION PROCEDURES

Procedure Number: PLTIP-001-GEN

KUWAIT OIL COMPANY

INDUSTRIAL SERVICES GROUP

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

DOCUMENT CONTROL LOG:

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

Inspection is a critical component of successful operation and maintenance of oilfield

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

i. All KOC equipment is in optimum operating condition (i.e., operate safely

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

iii. Effective maintenance planning and scheduling is achieved with standard

(g) These procedures are structured to be both prescriptive- and performance-based

2.1 Terminology and Definitions

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

Inspection agency or organization personnel (inspectors) will typically be under the

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

3.1 KOC General

c) Ensuring the availability of resources, particularly trained, qualified (certified) and

d) Ensuring, by communication and awareness, that all inspection personnel understand

3.2 KOC Inspection and Corrosion Team

b) Implementing, reviewing and maintaining the inspection management system

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

d) Determining and implementing corrective actions necessary to achieve planned

3.3 KOC Senior Engineer

3.4 KOC Inspectors

b) Determining and ensuring that the requirements of applicable standards, regulations,

b) Determining and ensuring that the requirements of applicable standards, regulations,

4.0 Training and Qualifications

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

5.2 Safety Precautions

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

5.2.2 Other Safety Requirements

5.3 Inspection Program

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

5.3.2 Scope of Inspection Procedures

5.3.3 Focus of API Inspection Procedures

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

5.3.4 Focus of KOC Inspection Procedures

5.3.5 Inspection Tools and Processes

5.3.6 Types of Inspection

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

(b) Planned Inspection (Preventive Maintenance Surveys): This type of inspection

(c) Mothballing/De-Mothballing: This term is given to inspections that will be

5.3.7 Inspection Cycles

6.0 Data Requirements

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

There are none at this time.

7.0 Referenced Documentation

(b) Related Standards

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

PIPIP-005-PLT Procedures for Inspection of In-Plant Piping

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

PTEST-004-PIE Pressure Testing of Pipelines

Represents the current applicable inspection procedure

7.3 Industry Standards

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC

Inspection and Corrosion (I&C)

Inspection and Corrosion (I&C)