Engineering Procedure

SAEP-1135 29 December 2014

On-Stream Inspection Administration
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope…………………………………………… 2
2 Purpose………………………………………… 3
3 Conflicts and Deviations……………………… 3
4 Applicable Documents………………………… 4
5 Definitions………………………………………. 6
6 Instructions……………………….…………….. 9
7 Responsibilities………………………………. 20

Appendix A – OSI Workflow………….………….. 24

Appendix B – OSI Performance Roles
and Responsibilities……………………. 25
Appendix C – OSI Calculations Data
Management System………………….. 26
Appendix D – UT Spot Measurements…………. 27
Appendix E – UT Scan Measurements………… 28
Appendix F – UT Grid Measurements………….. 29

Previous Issue: 26 April 2009 Next Planned Update: 29 December 2019

Primary contact: Kakpovbia, Anthony Eyankwiere (kakpovte) on +966-13-8801772

Copyright©Saudi Aramco 2014. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

1 Scope

1.1 This Saudi Aramco Engineering Procedure (SAEP) describes the steps
necessary to operate and administer a program for on-stream inspection (OSI)
on monitoring of static equipment (assets). The design and set up of an OSI
program is excluded from this procedure and is covered in SAES-A-135.

1.2 OSI Monitoring in this SAEP primarily means the systematic monitoring of
process equipment, piping and pipelines for general and localized metal loss,
cracking, material properties change and other forms of asset deterioration.

1.3 A comprehensive OSI monitoring program includes mechanical equipment,

civil, and electrical equipment condition monitoring per SAEP-20.

1.4 The overall OSI Program is intended to collect and integrate the different types of
OSI data required for implementing an asset integrity program and predicting
remaining asset life. This includes preparing equipment for Test & Inspection
(T&I) shutdowns and reporting per SAEP-1161.

1.5 Equipment Scope

This procedure applies to process equipment and piping for process fluids,
hydrocarbon and similar flammable or toxic fluid services identified in SAEP-20
and also includes fixed equipment contained in Community and Operations
Support Facilities as stated in SAEP-309.

1.6 OSI Monitoring

The monitoring of equipment for wall thickness loss and for flaw development
(such as cracking and material properties change) is referred to as “OSI
Monitoring.” It is normally conducted using an appropriate NDT method whilst
the equipment is operating (i.e., on-stream), under pressure, or inaccessible for
internal inspection. The recommended internal inspection of fixed equipment,
particularly for internal conditions and associated maintenance and test work
during shutdowns, is referred to as “Equipment Inspection.” This type of
inspection, referred to in SAEP-20, is not covered in this document. It should be
noted that thickness monitoring, or other NDT performed during “Equipment
Inspection” becomes a part of the total OSI Program.

1.7 OSI Objectives

The objective of an OSI Program is to provide reliable safeguards against

unexpected failures that can jeopardize safety and production. An OSI Program
alone cannot prevent all asset failures, but when it is coordinated with other

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

measures, such as proper maintenance , corrosion control and integration into an

asset performance management program, the likelihood of failure can be
reduced to a minimal level. Through predictive OSI reports, the following are
realistic goals of an OSI Program:

1.7.1 Recommend Retirement or Corrective Action

OSI reports are issued to recommend equipment retirement or de-rating

and to recommend repair or other corrective action, as a result of
corrosion rates and remaining life calculations.

1.7.2 Decrease Downtime

Prior to T&I shutdown, OSI reports can be used to timely forecast the
replacement of components that are at or near retirement age.

1.7.3 Increase Runtime

OSI potentially allow safe extension of equipment runtimes.

1.7.4 Reliable OSI information will contribute information to:

1.7.4.1 Corrosion Control Program (SAES-L-133)

1.7.4.2 Risk Based Inspection Program (SAEP-343)

1.7.4.3 Asset Performance Management Program (SAEP-410)

1.7.4.4 T&I Planning and Reporting (SAEP-1161)

2 Purpose

This procedure identifies the mandatory requirements for administration of an

On Stream Inspection (OSI) program within Saudi Aramco operating facilities.
This procedure should not be viewed as a stand-alone document but as a part of the
company-wide asset management, corrosion control and risk management program.
This integrated approach will contribute to mitigation of catastrophic failure of assets
and help identify areas of potential loss in containment, leakage or flaw development.

3 Conflicts and Deviations

3.1 Any conflicts between this procedure and other applicable Saudi Aramco
Engineering Standards (SAES’s), Materials System Specifications (SAMSS’s),
Standard Drawings (SASD’s), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Chairman, Inspection Engineering Standards Committee of Saudi Aramco,

Dhahran.

3.2 Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Chairman, Inspection Engineering Standards
Committee of Saudi Aramco, Dhahran.

4 Applicable Documents

On-stream inspection shall comply with the latest edition of the references listed below,
unless otherwise noted.

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedules
SAEP-306 Assessment of the Remaining Strength of Corroded
Pipes
SAEP-308 Operations Inspection Unit Review
SAEP-309 Inspection of Community and Operations Support
Facilities Inspection
SAEP-343 Risk Based Inspection for In-Plant Static Equipment
SAEP-372 Plant Inspection Performance Index (PIPI)
SAEP-378 Electrical Inspection Requirements
SAEP-385 Operations Inspection Data Management Requirements
SAEP-410 Asset Performance Management Program
SAEP-1146 Manual Ultrasonic Thickness Testing
SAEP-1161 Testing and Inspection (T&I) Reporting Procedure

Saudi Aramco Engineering Standards

SAES-A-005 Safety Instruction Sheet
SAES-A-135 On Stream Inspection Requirements
SAES-L-133 Corrosion Protection Requirements for Pipelines,
Piping and Process Equipment
SAES-L-310 Design of Plant Piping
SAES-N-001 Basic Criteria, Industrial Insulation

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Saudi Aramco Best Practice

SABP-A-033 Corrosion Management Program (CMP) Manual

Saudi Aramco Inspection Procedures

00-SAIP-74 Inspection of Corrosion under Insulation and
Fireproofing
00-SAIP-75 External Visual Inspection Procedure
00-SAIP-76 Worksheet Control and Tracking Program
01-SAIP-01 Small Nipple Inspection Program

4.2 Industry Codes and Standards

American Petroleum Institute

API STD 510 Pressure Vessel Inspection Code: Maintenance
Inspection, Rating, Repair, and Alteration
API RP 570 Inspection, Repair, Alteration and Rerating of
In-Service Piping Systems
API RP 571 Damage Mechanisms Affecting Fixed Equipment in
the Refining Industry
API RP 572 Inspection of Pressure Vessels
API RP 574 Inspection Practices for Piping Components
API RP 578 Material Verification Program for New and Existing
Alloy Piping Systems
API RP 579-1 Fitness for Service
API 580 Risk Based Inspection
API STD 653 Tank Inspection, Repair, Alteration and
Reconstruction
API 584 Integrity Operating Windows

American Society of Mechanical Engineers

ASME B31.1 Power Piping
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids
ASME B31.5 Refrigeration Piping
ASME B31.8 Gas Transmission and Distribution Piping Systems

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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ASME B31.9 Building Services Piping

ASME SEC I Rules for Construction of Power Boilers
ASME SEC VIII D1 Boiler and Pressure Vessel Code
ASME SEC VIII D2 Alternative Rules

American Society of Testing and Materials

ASTM G46 Standard Guide for Examination and Evaluation of
Pitting Corrosion

5 Definitions

Authorized Inspector: An individual accepted by Saudi Aramco to perform specific

roles and tasks to identify weaknesses, deteriorations and code compliance of pressure
equipment, piping and appurtenances.

Components: Parts that make up a piece of equipment or equipment item. For example
a pressure boundary may consist of components (pipe, elbows, nipples, heads, shells,
nozzles, stiffening rings, skirts, supports, etc.) that are bolted or welded into assemblies to
make up equipment items.

Condition monitoring locations (CML): Designated areas on process equipment and

piping systems where periodic examinations are conducted. Previously, CMLs were
referred to as “thickness monitoring locations” (TMLs). CMLs may contain one or
more examination points. CMLs can be a plane through a section of piping, or a nozzle,
or an area where CMLs are located on a piping circuit.

Corrosion Allowance (Actual): Actual Corrosion allowance is equal to the actual wall
thickness minus the retirement or minimum wall thickness. This measurement may be
different than the ‘specified corrosion allowance’ found on the SIS prepared in accordance
with SAES-A-005 or other equipment drawings, prepared during the original design.

Corrosion Loop: A term to define equipment and piping grouped together that are
similar in their process environment, made of like material and are susceptible to the
same damage mechanisms.

Corrosion Loop Description: A description of the complete corrosion loop, inclusive

of process parameters from start to finish, listing the equipment within the loop and
function, existing corrosion control measures, materials of construction, potential
damage mechanisms per API RP 571, process limits and monitoring, corrosion rates
and monitoring. Refer to SAES-L-133.

Corrosion Loop Diagram: A pictorial color coded representation of the corrosion

loop description with damage mechanisms. PFD, P&ID’s are normally utilized to

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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depict corrosion loops. Refer to SAES-L-133.

Corrosion Rate: The rate of metal loss due to erosion, erosion/corrosion or the
chemical reaction(s) with the environment, either internal and/or external.

Corrosion Service Class: Is the class determined from estimated or measured corrosion
rate as outlined in SAEP-20 Table 1.

Corrosion Specialist: A person, acceptable to the Saudi Aramco Proponent Department,

who has knowledge and experience in corrosion damage mechanisms, metallurgy,
materials selection, and corrosion monitoring techniques, and their impact on the piping
system.

Corrosion Under Insulation (CUI): Corrosion under insulation, including SCC under
insulation. Refer to SAES-L-133.

Deadlegs: Components of a piping system that normally have no significant flow.

Piping sections that have potential for internal corrosion, due to flow stagnation.
Refer to SAES-L-310 for detailed criteria.

Examination point: (e.g., recording point, measurement point, test point) An area
within a CML defined by a circle having a diameter not greater than 2 in. (50 mm) for a
pipe diameter not exceeding 10 in. (250 mm), or not greater than 3 in. (75 mm) for
larger lines and vessels. CMLs may contain multiple test points.

Examiner: A person who assists the Inspector by performing specific Non-Destructive

Testing (NDT) on process equipment and piping system components but does not
evaluate the results of those examinations ,unless specifically trained and authorized to
do so by the owner or user.

General corrosion: Corrosion that is distributed more or less uniformly over the
surface of the piping, as opposed to being localized in nature.

Injection points: Locations where relatively small quantities of materials are injected
into process streams to control chemistry or other process variables. Injection points do
not include the locations where two process streams join (mixing tees).

Inspection: The external, internal, or on-stream evaluation (or any combination of the
three) of equipment and/or piping condition conducted by the authorized inspector or
his/her designee. Refer to API 572, API 574 and API 578.

Localized Corrosion: Corrosion confined to a limited area of the metal surface.

Long Term Corrosion Rate: Refer to API 570.

Minimum Required Thickness: The minimum allowed thickness at a CML. It is the

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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larger of the pressure design thickness per the ASME design codes listed in Section 4.2,
or the structural minimum thickness at a CML. It does not include thickness for
corrosion allowance, or mill tolerances. Alternately, minimum required thickness can
be reassessed using Fitness-For-Service analysis in accordance with API 579-1.

Mixing Tees: A piping component that combines two process streams of differing
composition and/or temperature.

On-Stream Inspection: An inspection performed from the outside of process systems

while they are on-stream using NDT procedures to establish the suitability of the
pressure boundary for continued operation. Refer to API 510, 653, and 570.

Piping Circuit: A section of piping that is exposed to a process environment of similar

corrosivity or expected damage mechanisms and is of similar design conditions and
construction material. A piping circuit is normally part of a corrosion loop and is
depicted with more detailed information on an OSI drawing to allow inspection
personnel to locate and identify CML’s under field conditions and manage sub-sets of
corrosion loop data. Complex process units or piping systems are divided into piping
circuits to manage the necessary inspections, calculations, and recordkeeping.

Piping System: An assembly of interconnected piping circuits that are subject to the
same set or sets of design conditions and is used to convey, distribute, mix, separate,
discharge, meter, control, or snub fluid flows. Piping systems also include pipe-
supporting elements but do not include support structures, such as structural frames and
foundations. Damage mechanisms such as crevice corrosion under supports, fretting,
vibration, thermal expansion involving bowing, inadequate support resulting in low
spots may be applicable to a piping system.

Remaining Corrosion Allowance (RCA): is equal to the actual wall thickness minus
the minimum design thickness.

Remaining Life: Refer to API 570.

Risk-Based Inspection (RBI): A risk assessment and management process that is

focused on inspection planning for loss of containment of pressurized equipment in
processing facilities, due to material deterioration. Refer to SAEP-343and API 580.

Scanning: An Ultrasonic Testing technique used to detect and locate the thinnest
thickness measurement, or cracking at a CML. Refer guidance contained in API 574.

Short Term Corrosion Rate: Refer to API 570.

Small-Bore Piping (SBP): Pipe or pipe components that are less than or equal to NPS 2.

Soil-To-Air Interface (S/A Interface): An area where increased external corrosion

can occur on partially buried pipe. The zone of the corrosion will vary depending on

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

factors such as moisture, oxygen content of the soil and the operating temperature.
The zone generally is considered to be from 12 in. (30 cm) below to 6 in. (15 cm) above
the soil surface. Pipe running parallel with the soil surface that contacts the soil is
included.

Subject Matter Expert (SME): A person with direct knowledge of what is done in the
job, what knowledge, skills, abilities and other characteristics (KSAOs) are required, and
the general background of persons who are able to do the job successfully. These may
include those currently doing the job, recent incumbents, those who supervise others
doing the job, and other acknowledged job experts. Consult Inspection Engineering
Standards Committee Chairman for applicable SMEs in relation to this standard.

Water-To-Air Interface (W/A Interface or Splash Zone): An area of a structure that

is frequently wetted due to waves and tidal variations.

6 Instructions

6.1 Comprehensive OSI Program: The Inspection Unit Supervisor will design a
facility specific comprehensive OSI program to be inclusive of the following
elements:

6.1.1 Process equipment, piping and pipelines per SAES-A-135.

6.1.2 Mechanical equipment (i.e., flares per SAEP-20).

6.1.3 Civil infrastructure per SAEP-20 and SAEP-309.

6.1.4 Electrical equipment per SAEP-20 and SAEP-378.

The Inspection Unit Supervisor will also incorporate information from other
programs such as maintenance, engineering assessments, corrosion engineering,
cathodic protection, coatings and other information considered necessary to
produce a comprehensive OSI program.

6.2 Process equipment, piping and pipelines: This section outlines instructions to
operate and administer an OSI program. This program is set-up using the
requirements of SAES-A-135 and SAES-L-133.

6.2.1 Review the existing OSI program and determine whether it was
established using one of following scenarios:

6.2.1.1 Prior to the introduction of SAES-A-135

6.2.1.2 Based on SAES-A-135, paragraph 6.2 RBI Assessment, or

6.2.1.3 Based on SAES-A-135, paragraph 6.2 non-RBI approach

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6.2.1.4 No OSI program formally exists.

6.2.2 If established prior to the introduction of SAES-A-135:

6.2.2.1 Perform periodic reviews on existing program in conjunction

with facility corrosion engineer for adequacy of credible
damage mechanisms and monitoring techniques. Plan and
implement compliance improvements.

6.2.2.2 Review existing program and determine that the number of

CMLs complies with the appropriate table of SAES-A-135 and
document a plan with an ETC to bring into compliance.

6.2.2.3 Optimize numbers of CML’s by addition or deletion as per the

requirements of SAES-A-135 and paragraph 6.7 of this
procedure.

6.2.2.4 Review overdue and due CML data and perform appropriate
NDT per the requirements of SAES-A-135. Investigate and
resolve any anomalous data or inconsistency. Issue defect
notification per 00-SAIP-76, if necessary.

6.2.2.5 Update OSI drawings and NDT measurement data in the SAP
Application for Inspection of Facilities (SAIF) program.

6.2.2.6 Analyze OSI data results and trends per paragraph 6.4 of this
procedure. Investigate and resolve any anomalous data or
inconsistency. Issue defect notification per 00-SAIP-76, if
necessary.

6.2.2.7 Issue any reports to management and others per paragraph 6.8
of this standard and your organization requirements.

6.2.3 If established based on SAES-A-135, (RBI Approach):

6.2.3.1 Conduct periodic reviews on existing RBI assessment in

conjunction with facility corrosion engineer for adequacy.
The reviews shall include, but not limited to, facility MOC
program, T&I and PM records, capital projects and all other
applicable records. Determine any additional requirements and
update RBI assessment as needed.

6.2.3.2 Perform appropriate NDT per the RBI assessment inspection

plan. Investigate and resolve any anomalous data or
inconsistency. Issue defect notification per 00-SAIP-76 ,if
necessary.

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6.2.3.3 Update RBI assessment per SAEP-343 (evergreen process) and

analyze OSI data results and trends per paragraph 6.4 of this
procedure. Issue defect notification per 00-SAIP-76, if
necessary.

6.2.3.4 Risk level changes between High, Medium-High, Medium,

Low will impact the amount of CMLs per Tables 1 below and
any changes in Risk assessment ranking would require review
and updating of existing CMLs.

6.2.3.5 Update OSI drawings and NDT measurement data in the SAP
Application for Inspection of Facilities (SAIF) program.
Update date of next inspection based on RBI inspection plan.

6.2.3.6 Issue any reports to management and others per paragraph 6.8
of this standard and your organization requirements.

6.2.4 If established based on SAES-A-135, (Non-RBI approach):

6.2.4.1 Follow the requirements of paragraph 6.2.2.

6.2.4.2 Determine if RBI is required per SAEP-343. If needed,

perform RBI and perform future OSI based on paragraph 6.2.3.

6.2.5 If no OSI program was established:

6.2.5.1 When capital, non-capital and expense projects under the

control of Engineering and Project Management have not
established an OSI program per SAES-A-135, then with the
formal documented concurrence of Proponent Operations
Manager, the responsibility to establish the OSI program is
transferred to the proponent.

6.2.5.2 The Proponent Inspection Unit Supervisor assumes roles in

SAES-A-135 normally fulfilled by Engineering and Project
Management and establishes a comprehensive OSI program
per SAES-A-135 if the Proponent Operations Manager has
formally concurred per paragraph 6.2.5.1.

6.3 CML Damage Mechanism Monitoring

6.3.1 General and Localized Thinning Damage Mechanisms

The way CMLs measurements are performed with ultrasonic probes

will have a short term influence on how accurately the location is
represented. The type of ultrasonic testing method should be entered in

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the Saudi Aramco approved OSI computer program (e.g., SAIF).

All NDT shall be performed per the requirements of the applicable Saudi
Aramco NDT procedure. All manual ultrasonic thickness testing shall
be per SAEP-1146.

In cases of apparent growth of measurement value where the growth is

no greater than the system calibration accuracy then the last
measurement value may be used. In cases where apparent growth is
greater than the system calibration accuracy, then all anomalous data
should be investigated and resolved prior to updating data in the Saudi
Aramco data management system.

6.3.1.1 Spot Monitoring

This method is only approved for use where the predicted damage
mechanism is general thinning as defined by API RP 571.

An area within a CML defined by a circle having a diameter

not greater than 2 in. (50 mm) for a pipe diameter not exceeding
10 in. (250 mm), or not greater than 3 in. (75 mm) for larger
lines and vessels wherein full area of the spot is scanned and the
thinnest reading is recorded. CMLs of this type usually are
identified by paint pen markings or some permanent method of
identifying the location. This location is indexed to points on
the isometric piping or equipment drawings, to repeatedly
monitor precisely the same CML positions. This ensures that
CML loss rates are determined and located accurately.
When using the spot method, it is very important to scan areas
nearby in order to be able to detect other places where
deterioration may be significant. Refer to Appendix D of this
procedure for sequence of spot measurements. Spot monitoring
is normally performed manually.

6.3.1.2 Scan Monitoring

This method is approved for use where the predicted damage

mechanism is general or localized thinning as defined by
API RP 571.

Scanned zone coverage shall be 100% of pipe diameter and

minimum length of one pipe diameter upstream and downstream
of the CML centerpoint. This coverage can be increased as
required or determined by the SME. CMLs are usually marked
right on the equipment as a band around a pipe or a rectangular
area on a vessel or tank and the whole area of the zone are

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scanned for the thinnest measurement. The advantage of the

scanning method is that it provides increased probability than
the spot method of locating localized corrosion. Refer to
Appendix E of this procedure for sequence of measurements.
Scanning may be manual, semi-automated or automated.

6.3.1.3 Grid Monitoring

The two methods of grid monitoring may be used where the

predicted damage mechanism is general or localized thinning
as defined by API RP 571.

Grids consist of a coordinate system of intersecting vertical and

horizontal lines temporarily drawn on a component, normally
of equal space intervals. They are referenced to a component
datum such as a weld or other feature.

Type A grid: the area within the grid is scanned and the lowest
thickness is recorded for that cell. Type A is normally suitable
for components where the monitoring of migration or
development of localized corrosion is required.

Type B grid: a spot thickness measurement is taken at each

intersecting line. Type B is normally suitable for components
with uneven surface conditions such as landing bases and other
rough surfaces such as external of excavated pipelines.

Refer to Appendix F of this procedure for sequence of grid

measurements and SAES-A-135. Scanning may be manual,
semi-automated or automated.

6.3.2 Non-Thinning Damage Mechanisms

Each CML will have a specific damage mechanism as identified by the

Corrosion Engineer per SAES-L-133; SABP-A-033 Table 9 or per
SAEP-20, Table 1, Note 2; or by an RBI assessment per SAEP-343
(corrosion loop description and diagram). Examples include cracking
mechanisms, or material properties change such as embrittlement.
Each CML may not be a physical measurement but rather an evaluation
that will trigger an action or sequence of actions as follows (the various
techniques are identified in API 571):
● A Fitness for Purpose Assessment (SAEP-306 for Pipelines)
● Engineering Evaluation for fitness for purpose (for piping, vessel,
drums and tanks, etc., per API-579-1)

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● Modified Inspection Plan

● Root Cause Analysis (RCA)
● RBI Update Assessment
● Reduced Inspection Interval

6.3.3 CML Location and Access Requirements

6.3.3.1 Depending upon expected pattern of corrosion, all CMLs shall

preferably be located at locations readily accessible from
existing grade, platforms, and access ladders to minimize
scaffolding requirements.

6.3.3.2 Insulated piping and equipment requiring spot type thickness

measurements shall have insulation windows installed per
SAES-N-001, paragraph 8.

6.3.3.3 Insulated piping and equipment requiring scan or grid type

thickness measurements shall preferably have removable
insulation type installed per SAES-N-001, paragraph 8.

6.3.3.4 Mesh personnel protection guards used on hot piping should

preferably be of the removable type. If not, access holes with
covers will be required at CML locations.

6.4 Analyze OSI Data and Trends and Record Results

For General and Localized Thinning Damage Mechanisms, once two or more
successive thickness readings are available, OSI measured CML and
equipment/circuit information can be calculated manually or automatically by
the SAP Application for Inspection of Facilities (SAIF) program for each CML
component are:

6.4.1 CMLs
● Long Term Corrosion Rate
● Short Term Corrosion Rate
● CML Retirement Date
● CML Recommended Inspection Date
● Remaining Life Calculation

6.4.2 Component (EQ/CIRC)

Corrosion rates based on component measurements are derived from a

statistical analysis of the CML data. The type of statistical analysis will

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depend on the corrosion profile and many have proven benefits.

However the methods used have to be appropriate to the corrosion data
collected. A study will be conducted to find the best statistical fit for
Saudi Aramco’s facilities. When these statistical methods have been
reviewed and approved for use within Saudi Aramco this document will
be updated to include such calculations.

6.5 CML Scheduling

6.5.1 After Components have been baseline-measured, noted for flaws, and the
Corrosion Class has been estimated, the first monitoring dates can be
determined. This allows the initial monitoring dates to fit the expected
corrosion conditions as shown by the Corrosion Class.

6.5.2 The schedule of CMLs inspection is defined by piping service class

according to API 570, paragraph 6.3.4. This defines the Piping Service
Class as “Such a Classification system allows extra inspection efforts to
be focused on piping systems that may have the highest consequences if
failure or loss of containment should occur.”

6.5.3 A minimum of three (3) thickness measurements (Including Baseline),

are required before changing from an estimated corrosion rate to a
measured corrosion rate.

6.5.4 If the initial measured corrosion rate exceeds the estimated corrosion
rate, additional follow up inspection should be performed to validate the
findings.

6.5.5 The maximum inspection intervals based on OSI data are as listed in
Table 1 below:

6.5.5.1 Small Bore Piping (SBP) inclusive of nipples shall be

examined at the frequencies specified in 01-SAIP-01.

6.5.5.2 Corrosion Under Insulation and Fireproofing shall be examined

at the frequencies specified in SAEP-20, paragraph 4.5.8
following the guidance in 00-SAIP-74.

6.5.5.3 Structures shall be externally examined at the frequencies

specified in SAEP-20, paragraph 4.5.8 following the guidance
in 00-SAIP-75.

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Table 1

Maximum OSI Inspection Interval based on OSI Data Maximum Initial

Corrosion Service
OSI Interval
Class Remaining Life (Years) OSI Inspection Intervals (Months)
Less than or Less than or equal
Class 0 Remaining life divided by 2
equal to 4 years to 12 months
Class 1 >4 years to 10 years Remaining life divided by 2 12 months
Class 2 >10 years to 20 years Remaining life divided by 2 12 months
Class 3 >20 years Max 120 months 24 months
Injection Point N/A 36 months 24 months
Deadleg N/A By Corrosion Class 24 months
Small Bore Piping
N/A Refer paragraph 6.5.5.1 24 months
(SBP) and Nipples
Corrosion Under
N/A Refer paragraph 6.5.5.2 24 months
Insulation/Fireproofing
Structures N/A Refer paragraph 6.5.5.3 Per SAEP-20

6.5.5.4 The maximum inspection intervals can also be based on the

recommended Inspection Plan from a current RBI assessment.
The inspector will input the inspection interval into the SAIF
computer program which will then schedule the CML for
inspection.

6.5.5.5 In the absence of OSI data, or an Inspection Plan from an RBI

assessment the scheduling of CMLs can be defined based on
the results of a comprehensive review as required by paragraph
6.6 of this procedure.

6.5.5.6 CML scheduling will be performed per SAEP-385 upon the

availability of the SAP system.

6.6 Comprehensive Review

6.6.1 The OSI program is not a static system and will change over time as the
corrosion profile of the equipment changes. These changes shall be
reflected in the number, location and NDT method of the CMLs per
component. The Corrosion Engineer and Inspection Supervisor (or
delegate) shall review the OSI program on an annual basis to refine the
number and location of CMLs in a comprehensive review. Appendix A
flow chart identifies one possible scenario for performing and optimizing
an OSI program.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

6.6.2 A comprehensive review of the OSI program shall be performed in lieu of

an RBI assessment (if determined not required by SAEP-343 Appendix 1),
before an EIS deviation or revision. The review shall include but not be
limited to the following:

6.6.2.1 Compare the P&IDs to the OSI drawings to verify all required
piping circuits and equipment are included in SAIF. Any missing
must be added with UTT or scanning performed at scheduled
intervals per paragraph 6.5.5 Table 1 of this procedure.

6.6.2.2 Review the deviations of the plant Integrity Operating Window

(IOWs), if available, to make necessary adjustment to the OSI
program.

6.6.2.3 Review all CML readings for accuracy. Any readings that are
questionable must be verified.

6.6.2.4 Review the NDT technique used for each CML to ensure it is
appropriate to inspect for the damage mechanism type.

6.6.2.5 Review the number and location of each CML to ensure proper
monitoring.

6.6.2.6 Review all past internal and external inspection reports.

6.6.2.7 Optimize the number of CML based on the criteria listed in

paragraph 6.7 of this procedure.

6.6.2.8 Verify or update the T-min of each CML.

6.6.2.9 Review the results and robustness of the small diameter nipples
monitoring program.

6.6.2.10 Review the results and robustness of the dead-legs monitoring

program.

6.6.2.11 Review the results and robustness of the chemical injection

monitoring program to ensure it meets API 570 and API 510
guidelines.

6.7 OSI Program Optimization

CML Optimization shall be implemented after each RBI Assessment or every

5 years whichever occurs first, using the following criteria:

6.7.1 No more than 50% of CML for thinning shall be removed from an

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

existing OSI monitoring program at each RBI assessment or

comprehensive review.

6.7.2 Only uniform thinning CML are included.

6.7.3 Non-uniform corrosion such as chemical injection locations, small

diameter locations and dead legs shall be excluded.

6.7.4 LOW RISK class 3 components are re-evaluated.

6.7.5 MEDIUM RISK components with a probability of 1 and are class 3 per
SAEP-20 criteria are re-evaluated..

6.7.6 Measured circuits with a minimum of three inspections are re-evaluated.

6.7.7 Inspection technique must be able to detect the damage mechanism type
(localized corrosion - scanning, etc.).

6.7.8 CUI program in place for external corrosion is considered.

6.7.9 Evaluate locations for proper location to detect damage mechanism

(local or general corrosion).

6.7.10 Must have a minimum of five (5) CML.

6.7.11 Only shell CML are eligible for vessels and fin fans, no reduction for
nozzles.

6.8 Reporting

6.8.1 All OSI data reporting shall be addressed to the Supt. Operations with
copies to the Plant Manager, Engineering Supt. and Maintenance Supt.
Proponent local reporting needs may only modify the distribution list of
copies.

6.8.2 A quarterly OSI status report on overdue CMLs , or CMLs with a

corrosion rate greater than or equal to 0.12 mmpy (5 mpy) shall be
issued, showing location, minimum acceptable thickness and current
thickness. This report shall not be combined with any other report.

6.8.3 An Annual OSI status report shall be prepared to show progress made
during baseline and regular OSI monitoring. An updated master list of
all components due for retirement within the approved T&I interval
years should be included in the report. This report can be part of other
regular Inspection Unit Reporting.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

6.8.4 Once OSI data has been gathered and analyzed, reports can be prepared
by computer into one or more of the following types of reports.

6.8.4.1 New Survey

This report lists wall thickness measurements for each CML

for a given component and monitoring period. Also, this report
is designed to be printed out and used as a form to collect data
on the next monitoring trip.

6.8.4.2 CML Due for Inspection

This report can be generated for a specific time frame to show

what CMLs for various circuits or vessels are due to be
monitored (e.g., a report could be generated to show what
CMLs for various circuits are due to be monitored during a
specific month/year.) The next OSI should not be longer than
half the remaining life of the equipment.

6.8.4.3 Component Due for Retirement

This report can be generated for a specific time frame to show

what components are due to be retired based on the CML with
the lest remaining life (e.g., a report could be generated to
show what components are due for retirement during a specific
month/year) The report includes the circuit retirement date and
the next inspection due date.

6.8.4.4 CML Due for Retirement

This report can be generated for a specific time frame to show

what CMLs for various components are due to be retired.
(e.g., a report could be generated to show what CMLs for
various components are due for retirement during a specific
month/year.) The report includes the CML retirement date for
each component and the next inspection due date.

6.8.4.5 Annual Report

This report illustrates all thickness readings and the dates taken
for each CML by area and component. It also includes the
corrosion class, the long and short term corrosion rates, the
remaining life, next inspection date and shall include
equipment condition.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

6.8.4.6 Overdue Report

This report displays all CML that are overdue for inspection
showing corrosion class, long and short term corrosion rates,
the remaining life and the planned inspection date.

6.8.4.7 CMLs with a Corrosion Rate Greater than or Equal to

0.12mmpy (5 mpy)

This report has the same information as the 3 in 1 report, only

the data is shown for CMLs with either a long or short term
corrosion rate greater than or equal to 0.12 mpy (5 mpy).

6.8.5 To avoid unexpected rupture, Fitness-For-Service (FFS) evaluations

shall be conducted using OSI data for all CMLs that are less or at Tmin,
and the following shall apply:
(a) The FFS shall be conducted by the operating department Specialist
Unit mechanical engineer.
(b) FFS Reporting requirements shall follow API-579-1. Examples of
special reporting needs include API-579-1 Section 6 pitting grading
charts and ASTM G46.

6.8.6 During OSI, it will be necessary to make changes and revisions to the
program, CML’s, drawings, etc., and all changes should be in
accordance with the requirements of SAES-A-135.

6.8.7 CML reporting shall be performed as per SAEP-385 upon the

availability of the SAP system.

7 Responsibilities

7.1 Operations Inspection Unit Supervisor

7.1.1 Assures an active OSI Program and responsible for the planning and
administering of the OSI Program within his area of responsibility.

7.1.2 Assures the availability of an active OSI program and all unit personnel
have access to the program for the required action.

7.1.3 Assures the availability of a training program to maintain effective

administration of the OSI Program.

7.1.4 Ensures a comprehensive review of the OSI program has been performed
a minimum of every ten years to ensure its robustness.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

7.1.5 Ensures optimization of the CMLs in the OSI program after every RBI
assessment, or comprehensive review.

7.1.6 Issues the quarterly OSI Status Report.

7.1.7 Issues the annual OSI Report.

7.1.8 In case, the Unit has no assigned Corrosion Engineer, the Unit
Supervisor shall seek the support of either a qualified engineering service
provider or CSD.

7.2 Corrosion Engineer with Assistance from the Process Engineer

7.2.1 Develops the corrosion loops per SAES-L-133 using the process flow
diagrams and descriptions per SAEP-343 paragraph 6.2.1.

7.2.2 Estimates corrosion rates for each component that does not have a
measured corrosion rate.

7.2.3 Assigns CMLs to each component so that the quantity and location
matches the expected or known corrosion class.

7.2.4 At least review corrosion rates greater than 0.12 mpy (5 mpy) annually
or components with remaining life less than twice the OSI interval and
issue a report of the review to the Inspection Supervisor.

7.2.5 Reviews the impact of process changes on OSI Program (optimization)

and adjust the CML’s or intervals as required. The corrosion engineer
shall revise the OSI data and assigned interval in case of Plant Integrity
Window (PIW) changes.

7.2.6 Reviews the result of CML surveys and set next inspection intervals
according to comprehensive review, or RBI.

7.3 OSI Administrator Role

7.3.1 Role can be performed by one or more individuals provided all

administrators have different organizational or geographical
responsibilities.

7.3.2 Planning and running of the OSI Program.

7.3.3 Issues the required OSI progress reports and OSI CML overdue reports
to the Unit Supervisor.

7.3.4 Coordination of NDT actions between the area inspectors and the NDT
technicians.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
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Next Planned Update: 29 December 2019 On-Stream Inspection Administration

7.3.5 Reports mismatched and/or unexpected corrosion rates to Unit

Supervisor and the Corrosion Engineer through formal reports or email
notifications.

7.3.6 Coordinates all activities associated with the SAIF program.

7.3.7 Reviews data entered into the SAIF program.

7.4 Field Supervisor

7.4.1 Field Supervisor is generally assigned the OSI Coordinator role

dependent upon the organizational needs of the proponent.

7.4.2 Assures all plant static equipment is monitored by OSI program

according to schedule specified in this procedure.

7.4.3 Reviews OSI data with the responsible Area Inspector and advise
accordingly.

7.4.4 Ensures OSI program data is reviewed, analyzed, and added to the
equipment per T&I reports.

7.5 Area Inspector

7.5.1 Conducts or coordinate baseline survey with others to obtain original

wall thickness measurement of new, modified or previously unmonitored
equipment.

7.5.2 Reviews OSI data periodically (at least monthly) and plan/coordinate all
resources necessary to complete OSI with no overdue CMLs.

7.5.3 Obtains wall thickness measurement of the monitored plant equipment as

per OSI due reports.

7.5.4 Requests for preparation of OSI isometric drawings of new piping and
equipment.

7.5.5 Requests for modification of existing OSI Isometric drawings to reflect

the as-built condition.

7.5.6 Updates or coordinates SAIF program and/or the RBI database with the
latest CML measurements and results of all inspections.

7.5.7 Verifies all data entered into SAIF and/or the RBI database.

7.5.8 Issues Defect Notification (previously Worksheets) as needed.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

7.6 Inspection Department

Reviews the OSI program during OIU review in accordance with SAEP-308.

Revision Summary
29 December 2104 Major revision.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Appendix A – OSI Workflow

SAES-A-135

SAEP-1135
Perform OSI for CML
All OSI steps or NDT as required to
map corrosion and validate damage
mechanisms

Analyze, Trend and Record Results

Map and Report in Approved Data
Management System;
perform FFS (if necessary)

Evergreen RBI Database

if applicable

Schedule Next Inspection

Based on results

Damage Other
Mechanism Damage
Mechanism
Metal
Loss

Class No
0 or 1

Yes Last OSI

No
10 Years
ago

Yes

Comprehensive Review
SAEP-1135
MOC, Deviations, Schedule
Revisions, APM, Audit Results.

Optimize OSI Program

SAEP 1135

No Any changes
to CMLs?

Yes

SAES-A-135

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Appendix B – OSI Performance Roles and Responsibilities

Department R Performs the task

Procedure A Accountable for the task being

completed

Updated S Supports

C Consulted prior to the task being

performed

I Informed that the task has been

completed

supervisor

Insp. Field
Inspection

Corrosion
Inspector

Engineer
Division

Supv.
Head

ID
Paragraph Description

Perform OSI Measurements. I I A R S S

Analyze trend and record results I A S S R S

Evergreen RBI database if applicable I A S S R S

Schedule next inspection I I A R S S

Perform Comprehensive Review (If required) I A S S R S

Optimize OSI Program I A S S R S

Document changes on the OSI program as per I A S S R S

SAES-A-135 if required

Review the OSI program during the unit review in I S S S S A

accordance with SAEP-308.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Appendix C – OSI Calculations Data Management System

C.1 SAP Application for Inspection of Facilities (SAIF) program shall be used for
conducting OSI Program calculations and scheduling. Some of the basic
calculations performed by SAIF are identified in this section. For a detailed
description of these calculations refer to API 570 paragraph 7.1.1

C.2 Calculations Made for Each CML

● Long Term Corrosion Rate
● Short Term Corrosion Rate
● CML Retirement Date
● CML Recommended Inspection Date
● Remaining Life Calculation
● Maximum Allowable Working Pressure

C.3 Calculations Made for the Complete EQ/CIRC ID

Corrosion rates based on whole circuit measurements are derived from a

statistical analysis of the TML/CML. The type of statistical analysis will
depend on the corrosion profile and many have proven benefits. However, the
methods used has to be appropriate to the corrosion data collected. A study will
be conducted to find the best statistical method fit for Saudi Aramco’s facilities.
When these statistical methods have been reviewed and approved for use within
Saudi Aramco, this document will be updated to include such calculations.

C.4 T-min calculations are performed for Piping, Vessels, Power Boilers and Tanks.
These calculations are based on formulas from the industry standards governing
their design. Refer to section 4.2 for a list of applicable ASME codes.

C.5 Structural T-min is obtained from SAES-L-310 paragraph 10.4 Table 1 and
paragraph 10.5 Table 2.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Appendix D – UT Spot Measurements

Guidance for CML Spot Thickness Measurement Numbering Sequence

1
Upstream Weld Downstream
1 Sequence
Right Hand Rule
Imaginary grip of pipe-
Flow Thumb points in
2,4 direction of flow, fingers
4 2
point in sequence of
measurement location
numbering.

3
3

NORTH
Flow

Downstream

1
1,3
2, 4
Weld

2 4

Upstream

Note 1: Up to and Note 2: Up to and

including 45 degrees from including 45 degrees from
horizontal treat as vertical, treat as vertical,
horizontal, above 45 above 45 degrees treat as
degrees treat as vertical horizontal.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Appendix E – UT Scan Measurements

UPSTREAM WELD DOWNSTREAM 0

FLOW 270 90

1D 1D 180

90

180

270

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1135
Issue Date: 29 December 2014
Next Planned Update: 29 December 2019 On-Stream Inspection Administration

Appendix F – UT Grid Measurements

UPSTREAM WELD DOWNSTREAM 0

FLOW 270 90

1D 1D 180

TYPE A GRID

0 1 2 3 4 5 6 7 8 9 10 11 12
A 0
B
C
D 90
E Each square
F scanned & T
G 180 minimum
Recorded for
H
each square
I
J 270
K
L
M 0

TYPE B GRID

0 1 2 3 4 5 6 7 8 9 10 11 12
A 0
B
C Intersection of
each grid spot
D 90
measurement &
E recorded
F
G 180
H
I
J 270
K
L
M 0

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