GASCO Inspection Corrosion Management Standard

Inspection, Corrosion & Metallurgy Department (Engineering & Technical Services Division)

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TABLE OF CONTENTS Section No. 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.6.1 1.6.2 2. 2.1 2.1.1 2.2 2.2.1 2.2.2 2.2.2.1 2.2.2.2 2.2.2.3 2.2.2.4 2.2.2.5 2.2.2.6 2.2.2.7 2.2.2.8 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.4 2.5 3.

Description INTRODUCTION Purpose and Objectives Scope Intended Users Definitions Acronyms Regulatory Requirements and References GASCO Documents ISO International Standard on Risk Management INSPECTION & CORROSION MANAGEMENT FRAMEWORK General ICMS and Risk Management Documents of Inspection & Corrosion Management System Document Hierarchy Guidelines, Recommended Practices, and Procedures Business Process Flow Documents Guideline Documents Recommended Practice (RP) Documents Common Inspection Procedures Site-Specific Inspection Procedures Associated Procedures Internal Corrosion Management Procedures External Corrosion Management Procedures Description of the Inspection and Corrosion Management Framework Policy Context Organization Accountability Resources Communication Process Integration Continuous Improvement Implementation of Inspection & Corrosion Management Standard Risk Based Inspection (RBI)

INSPECTION AND CORROSION MANAGEMENT PROCESS

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TABLE OF CONTENTS Section No. 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.1.1 3.2.1.2 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.3.3.1 3.4 3.4.1 3.4.1.1 3.4.1.2 3.4.1.3 3.4.1.4 3.4.1.5 3.4.1.2 3.4.2 3.4.3 3.4.3.1 3.4.3.2 3.4.4 3.4.5 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.6 3.6.1 3.6.2 3.6.3

Description Scope and Context Asset Identification Strategy and Delivery Integration with Risk and Integrity Management Degradation Threat Assessment Threat Identification Internal Corrosion External Corrosion Threat Analysis Threat Response Selection Implementation Management Internal Corrosion Pressure Equipment Protection Verification Pressure Vessels Pre-commissioning Inspection Warranty Inspection Subsequent Inspections Inspection Activity Variation Control Pressure Relief Devices Registration Fitness-for-Service Pressure Vessels Pressure Relief Devices Repairs Deficient Conditions Communication and Consultation Planning Tracking Reporting Data Management Monitoring and Review Response Performance Criteria Response Program Feedback ICMS Program Performance

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TABLE OF CONTENTS Section No. 3.6.4 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.7 3.7.8 3.7.9 3.8.0 3.9 3.10

Description Program Improvement INSPECTION FREQUENCY OF SPECIALISED EQUIPMENT Reaction Furnaces (SRU) SRU Stacks Cold Boxes (Stacked Aluminum Brazed Heat Exchangers) Fired Process Heaters Underground Structure Corrosion Survey Storage Tanks Boilers Inspection

Lifting Equipment and Cranes Flame Arrestors External visual Inspection (EVI) Welding Works

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LIST OF FIGURES Figure No. Figure 1. Figure 2. Figure 3.

Description Inspection & Corrosion Management Process within the Context of an Inspection &Corrosion Management Framework GASCO Corporate Risk Assessment Matrix Illustration of Document Hierarchies in the Inspection and Corrosion Management System

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LIST OF APPENDICES Section No. Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G

Description ICMS and Other Management Systems Industry Reference Standards Register for Business Process Flow Documents Register of Guideline Documents Register for Recommended Practice Documents Register of Common Inspection Procedures Register for Associated Documents

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LIST OF APPENDICES Section No. Appendix H Appendix I Appendix J Appendix K Appendix L Appendix M

Description Register of Common Welding Procedures Organization Chart Registration of Pressure Protection Items Periodic Testing of Pressure Relief Items Identification Requirements for Pressure Protection Equipment Inspection Activity Variation Control Forms

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SECTION 1 INTRODUCTION

The Inspection and Corrosion Management Standard (ICMS) contains the strategies required to effectively manage inspection and corrosion throughout GASCO’s production facilities within the UAE. In the hierarchy of Integrity Systems, the ICMS supports GASCO’s Asset Integrity & Reliability Management System (AIRMS) Manual, the Asset Integrity Management Policy, and the Inspection and Corrosion (I & C) Management Policy in defining the requirements for managing corrosion related degradation. At the Corporate level, the ICMS fulfills the requirements of GASCO Business Plans, the Shareholder Directives and the ADNOC Code of Practice. The details of the relationship of ICMS with other Management Systems are given in Appendix A.

1.1 Purpose and Objectives The purpose of the ICMS is to provide strategies as well as direction and guidance for Inspection & Corrosion Management of GASCO’s physical assets. By doing so, the Standard document provides a roadmap for following the Inspection & Corrosion Management Policy as well as providing compliance with the requirements of ADNOC Code of Practice (CoP) V6-01 and the HSE Management System. The ICMS aims to maintain the integrity of GASCO assets using a risk-based approach of identification, analysis, assessment, prevention and mitigation of degradation risks, which may adversely affect health, safety, environment, reputation and asset integrity. The Standard references tools for determination of likelihood of degradation which, when coupled with the Consequences of Failure (CoF), provide the overall assessment of both unmitigated and mitigated risk. Risk Based Inspection (RBI), which determines risk by addressing both the likelihood of threats or Probability of Failure (PoF) and the Consequence of Failure (CoF) shall be the basis of GASCO’s I & C Management.

1.2 Scope

The requirements specified within this document apply to all activities related to ICMS practices as applicable to static pressure containing equipment including vessels, plant piping, pipelines and structures across the entire GASCO production facilities in Asab, Buhasa, Habshan/Bab, and Ruwais. The ICMS is structured on a framework of central elements to ensure the effectiveness and consistency of programs, based on the following principles: a.

Create and protect value.

b.

Be an integral part of all GASCO management processes.

c.

Be part of the decision making process to make risk-based choices and to prioritize actions.

d.

To fully comply with ADNOC Group norms, industry regulations, codes and standards

e.

Be systematic, structured and timely.

f.

Be based on the best available information, such as historical data, experience, stakeholder feedback, observations, forecasts and subject matter expert (SME) judgment.

g.

Be aligned with GASCO’s external and internal context and risk profile.

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h.

Be transparent and inclusive by appropriate and timely involvement of stakeholders and decision makers at all levels of GASCO’s organization.

i.

Continuously monitor and respond to change caused by internal and external events.

j.

Facilitate continual improvement by developing and implementing strategies to improve GASCO’s degradation risk management of pressure equipment.

1.3 Intended Users The ICMS is administered by the Inspection, Corrosion & Metallurgy department, and is intended for use by its own staff and the staff from other Operations, Maintenance or Technical Departments directly associated with any Inspection and Corrosion Management related activities.

1.4 Definitions Asset Owner

The asset owner is the person or group of people who have been identified by management as having responsibility for the maintenance of the confidentiality, availability and integrity of an asset. The asset owner may change during the lifecycle of the asset.

Business Process Flow Diagrams (BPFD)

Are simplified diagrams that clearly show the required interactions between several departments for a specific Business Process e.g.: Inspection and Corrosion Management.

Code

The American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, unless specified otherwise

Common Inspection Procedures

Are detailed documents which have been developed to provide a ‘Common Language’, Common Understanding’ & ‘Uniform Implementation’ for the Majority of Inspection practices that are to be consistently applied across all of the GASCO operational facilities.

Company

Abu Dhabi Gas Industries Ltd. (GASCO)

Corrosion

Deterioration of metal by chemical or electrochemical reaction with its environment

Damage

A phenomenon, which induces deleterious micro and/or macro material changes that are harmful to the material condition or structural properties. Damage mechanisms are usually incremental, cumulative, and unrecoverable. Common damage mechanisms are associated with chemical attack (or corrosion, and the special case of stress-corrosion), creep, erosion, fatigue, fracture, and thermal aging.

Degradation

The reduction in the ability of a component to provide its intended purpose of containment of fluids or gases. This can be caused by various damage mechanisms (e.g., corrosion, cracking, mechanical).

Documents

Technique, material, application, and/or a set of instructions that are considered to be the current Best Practice in our industry, available for a specific task &/or situation. They are not mandatory but provide proven techniques to overcome particular situations.

Framework

Broad overview, outline, or skeleton of interlinked items which supports a particular approach to a specific objective, and serves as a guide that can be modified as required

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Guideline Documents

Are a clear set of instructions that provide the Minimum and Mandatory requirements for implementing a specific task and/or management system, e.g.: The implementation of S-RBI requirements across our sites.

Inspection

An inspection is generally, an organized examination or formal evaluation exercise. It involves measurements, tests, and gauges applied to certain characteristics in regard to an object or activity. The results are compared to specified requirements and standards for determining whether the item or activity is in accordance with the stated requirements, Inspections are usually non-destructive.

Inspection & Corrosion Management

A vital part of the overall integrity management system, which is concerned with development, implementation, review & maintenance of the corporate Inspection and Corrosion Management System.

Management System

Documented and tested step-by-step method aimed at smooth functioning through standard practices. Management systems generally include detailed information on topics such as (1) organizing an enterprise, (2) setting and implementing corporate policies, (3) establishing accounting, monitoring, and quality control procedures, (4) choosing and training employees, (5) choosing suppliers and getting best value from them, and (6) marketing and distribution.

Non Destructive Testing (NDT)

Is a wide group of analysis techniques used in industry to evaluate the properties of a material, component, or system without causing damage. Because NDT does not permanently alter the equipment being inspected, it is a highly-valuable technique that provides important data regarding the condition of the equipment. Conventional NDT methods include DPT, MPI, RT, & UT.

Plan

Written account of intended future course of action (scheme) aimed at achieving specific goal(s) or objective(s) within a specific timeframe.

Pressure Equipment

Is defined as a vessel, piping, safety accessories and pressure accessories, where applicable, pressure equipment includes elements attached to pressurized parts such as flanges, nozzles, couplings, supports, lifting lugs, etc.

Pressure Protection Systems

Pressure protection systems are designed to prevent over-pressurization. They will shut off the source of the high pressure before the design pressure of the system is exceeded, thus preventing loss of containment through rupture of a line or vessel. Thus, a pressure protection system is considered as a barrier between a high-pressure and a low-pressure section of an installation.

Pressure Relief Systems

A pressure relief system will open an alternative outlet for the liquids in the system once a set pressure is exceeded, to avoid further build-up of pressure in the protected system. This alternative outlet generally leads to a flare or venting system to safely dispose the excess fluids.

Procedure

A fixed, step-by-step sequence of activities or course of action (with definite start and end points) that must be followed in the same order to correctly perform a task. Repetitive procedures are called routines.

Process

Sequence of interdependent and linked procedures which, at every stage, consume one or more resources (employee time, energy, machines, money) to convert inputs (data, material, parts, etc.) into outputs. These outputs then serve as inputs for the next stage until a known goal or end result is reached.

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Program

A plan of action aimed at accomplishing a clear business objective, with details on what work is to be done, by whom, when, and what means or resources will be used.

Recommended Practice Documents

Are "best practices" or "guidelines" documents for methods, Metallurgy, or practices in order to give guidance to the user. These documents usually represent a leading edge, exceptional model, or a proven industry practice. Use of any or all elements of a Recommended Practice is discretionary; it may be used as stated or modified by the user to meet specific needs.

Specialized NDT techniques

As an example, eddy current, phased array, Slofec, etc.

Stress corrosion cracking

Failure by cracking under the combined action of corrosion and stress, either external or internal. Cracking may be either intergranular or transgranular depending on the metal and the corrosive medium.

Inspection, Corrosion & Metallurgy Department (Engineering & Technical Services Division)

1.5 Acronyms

AIRMS

Asset Integrity and Reliability Management System

ALARP

As Low As Reasonably Practicable

ANSI

American National Standard Institute

API

American Petroleum Institute

ASCMS

Asset Specific Corrosion Management Strategy

ASME

American Society of Mechanical Engineers

ASP

Asset Specific Procedure

ASTM

American Society for Testing of Metallurgy

BPF

Business Process Flow

B&PV

Boiler and Pressure Vessel

CCM

Corporate Corrosion Management

CES

Critical Equipment and Systems

CIP

Common Inspection Procedure

CIPS

Close Interval Potential Survey

CoF

Consequence of Failure

CoP

Code of Practice

CP

Cathodic Protection

CRA

Corrosion Resistant Alloy

CUI

Corrosion under Insulation

DCVG

Direct Current Voltage Gradient

DGS

Design General Specification

DPT

Dye Penetrant Testing

ECDA

External Corrosion Direct Assessment

EFC

European Federation of Corrosion

ELT

GASCO Extended Leadership Team

EMS

Environmental Management System

ERMS

Emergency Response Management System

ETS

Engineering and Technology Support

FIMS

Facility Integrity Management System

FFS

Fitness-for-Service

FMPI

Fluorescent Magnetic Particle Inspection

GRIATS

GASCO Reliability and Integrity Action Tracking System

HSE

Health Safety and Environment

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Inspection, Corrosion & Metallurgy Department (Engineering & Technical Services Division) HSEMS

Health Safety and Environment Management system

HSECES

HSE Critical Equipment Systems

ICCP

Impressed Current Cathodic Protection

ICDA

Internal Corrosion Direct Assessment

ICMM

Inspection & Corrosion Management Manual

ICMP

Inspection & Corrosion Management Policy

ICMS

Inspection & Corrosion Management Standard

IDMS

Inspection Data Management System

IMS

Integrity Management System

ISO

International Standards Organization

KPI

Key Performance Indicator

MAWP

Maximum Allowable Working Pressure

MMS

Maintenance Management System (MAXIMO)

MoC

Management of Change

MPI

Magnetic Particle Inspection

MTI

Metallurgy Technology Institute

NACE

NACE International – the Corrosion Society

NDT

Non Destructive Testing

NII

Non-Intrusive Inspection

OHMS

Occupational Health & Safety Management System

OME

Original Manufacturer Equipment

PEP

Pressure Equipment Protection

PIMS

Pipeline Integrity Management System

PM

Preventive Maintenance

PoF

Probability of Failure

PRV

Pressure Relieve Valve

QMS

Quality Management System

RAM

Risk Assessment Matrix

RBI

Risk Based Inspection

RCA

Root Cause Analysis

RP

Recommended Practice

RT

Radiographic Testing

SIMS

Structural Integrity Management System

SMS

Safety Management System

SCC

Stress Corrosion Cracking

SME

Subject Matter Expert

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Inspection, Corrosion & Metallurgy Department (Engineering & Technical Services Division) SOHIC

Stress-Oriented Hydrogen Induced Cracking

SSC

Sulfide Stress Cracking

TS

Technical Services

UT

Ultrasonic Testing

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1.6 Regulatory Requirements and References

The ICMS meets the requirements of ADNOC HSEMS Code of Practice, Volume 6, CoP V6-01: “Identification and Integrity Assurance of HSE-CES”. The ICMS also complies with international codes, specifications and standards, GASCO specifications and ISO 9001-2008 Quality Management Systems. Records for HSE-CES (and business critical systems) must be maintained for degradation monitoring and control activities to the standard contained in the ADNOC CoP. The design of HSE-CES (and business critical systems) must take into account corrosive environments and select Metallurgy for each component to be compatible with service and operating conditions. Mothballing and decommissioning of HSE-CES (and business critical systems) shall assure that the equipment remains in a safe condition while not in operation. The ICMS refers to the following:

1.6.1 GASCO documents: a.

GASCO Inspection & Corrosion Management Policy (June 2009)

b.

GASCO Asset Integrity Policy (January 2008)

c.

GASCO Asset Integrity & Reliability Management System – Framework (Rev. 1 November 2006)

d.

GASCO Business Plans

e.

GASCO Design General Standards

f.

GASCO Pipelines Division Operation Procedures

1.6.2 ISO international standard on risk management: a.

ISO 31000-2009 Risk Management – Principles and Guidelines (1st edition)

Reference is made in Appendix B to relevant Inspection and Corrosion API, ASME, NACE, and ISO Standards and Recommended Practices pertinent to GASCO’s Inspection and Corrosion management activities.

2. INSPECTION & CORROSION MANAGEMENT FRAMEWORK 2.1

General

The Inspection & Corrosion Management Standard (ICMS) consists of a core process of inspection and corrosion management. This core process is not a stand-alone system, and requires a framework for internal and external integration and linking with other management systems in its operating environment. The purpose of the ICMS is to integrate the process to create accountabilities, to identify resources, and to provide links to internal and external management systems. The core process of the Standard comprises three sub-processes namely scoping, assessing and responding to degradation risks. Figure 1 shows a diagram of the ICMS process within

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the ICMS framework, which is based on ISO 31000 – Risk Management. The elements of the ICMS are based on the structure and elements used in the GASCO AIRMS Framework Document, (doc. No.: EPL/AGM(O)/0003), are: a. b. c. d. e. f. g. h.

Policy Context Organization Accountability Resources Communication Process Integration Continuous Improvement

These elements are discussed in detail in Section 2.3. CORROSION & INSPECTION MANAGEMENT SYSTEM FRAMEWORK POLICY

CONTEXT

ORGANIZATION

COMMUNICATION AND CONSULTATION

SCOPE AND CONTEXT

THREAT ASSESSMENT

ACCOUNTABILITY

CONTINUOUS IMPROVEMENT

CORROSION & INSPECTION MANAGEMENT PROCESS

THREAT RESPONSE

MONITORING AND REVIEW

CIM PROCESS INTEGRATION

COMMUNICATION

RESOURCES

Figure 1 - Inspection & Corrosion Management Process within the Context of an Inspection & Corrosion Management Framework

2.1.1 ICMS and Risk Management The ICMS complements GASCO’s risk management policies and practices by focusing on the likelihood of degradation development, i.e. the threat of degradation due to corrosion. The principles of inspection and corrosion management are integrated with GASCO’s risk management program. The ICMS focuses primarily on identifying and reducing the likelihood of corrosion threats that could result in undesired or unanticipated consequences. The Site Specific Corrosion Management Strategy documents provide an overview of corrosion threats for individual assets. The GASCO RBI system (S-RBI) identifies the corrosion degradation modes, and establishes the respective inspection and testing strategies. By combining the Probability of Failure (PoF), or corrosion threat with the Consequence of Failure (CoF), a degree of risk can be assigned. There are different methods to assign the risk, ranging from a simple indexing system for pipelines, to decision tree development, to probabilistic modeling. Once a risk level has been assigned to a particular threat, this risk can be placed in GASCO’s Corporate Risk Assessment Matrix (RAM), see Figure 2. By placing specific risks into the Corporate RAM, the local risk can be related to corporate acceptance of risk.

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Figure 2 GASCO Corporate Risk Assessment Matrix

2.2 Documents of Inspection & Corrosion Management System The success of inspection and corrosion management depends on the effectiveness of integrating the ICMS with other relevant activities and objectives at different levels of GASCO’s organization. This requires that the ICMS and all its processes are documented. The documentation pertaining to ICMS are discussed in the sub-sections that follow.

2.2.1 Document Hierarchy The ICMS delivers GASCO’s Inspection and Corrosion management policies in the context of corrosion degradation management, and provides links to program processes and strategies, which support corrosion degradation management. Figure 3 shows the document hierarchy in the ICMS.

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Organization objectives, goals, commitments, accountabilities

POLICY

FRAMEWORK

Identifies key elements of each program and how programs fit together

PROCESS STRATEGY

Strategy documents describe how each process works to support the programs; may reference procedures

PROCEDURES

Procedures provide specific direction on how activities should be performed in each process

Figure 3 Illustration of Document Hierarchies in the ICMS At the policy level (see GASCO Inspection & Corrosion Management Policy), GASCO’s inspection and corrosion management objectives, goals, commitments and accountabilities are identified, while at the framework level (see Figure 1) the elements and sub-elements of the ICMS are identified and linked to the AIRMS framework elements and sub-elements, as well as the links to other management systems, see Figure A2 in Appendix A. At the process strategy level, the documents describe each process within the ICMS with reference to Procedures, providing specific directions on activities in each process.

2.2.2 Guidelines, Recommended Practices, and Procedures GASCO has developed guidelines, recommended practices and procedures that fall under the ICMS.

2.2.2.1 Business Process Flow documents have been developed to demonstrate the required interactions between GASCO departments for specific business processes. References to pertinent Business Flow documents are given in Appendix C–Register for Business Flow Documents. 2.2.2.2 Guideline documents have been developed to provide a detailed set of requirements that must be applied to ensure that approved management systems, such as S-RBI, will be implemented in a consistent manner across all of the GASCO operational assets. Mandatory requirements from each guideline document are described in the documents listed in Appendix D –Register of Guideline Documents. 2.2.2.3 Recommended Practice (RP) documents have been developed from current Best Practices within GASCO, the ADNOC OPCO’s, and the GASCO shareholder companies. The documents provide a detailed set of instructions on how to apply a defined task, use specific Metallurgy, apply a certain methodology, etc. in order to address know problem or situations. The RPs are not mandatory, but provide solutions for known problems; RPs are listed in Appendix E–Register for Recommended Practice Documents. 2.2.2.4 Common Inspection Procedures (CIPs) have been developed from: a.

Existing practices across the GASCO operational facilities

b.

Requirements from the ADNOC Codes of Practice

c.

International Standards

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Best industry practices and latest technologies, where considered appropriate

The CIPs are designed to provide common inspection procedures that must be consistently applied across all of GASCO’s assets. The CIPs are listed in Appendix F - Register of Common Inspection Procedures. 2.2.2.5 Site-Specific Inspection Procedures have been developed to meet site-specific inspection requirements. Where assets with unique facilities or equipment exist that require specific inspection procedures, the local Inspection group shall develop specific procedures to ensure that the asset is inspected and maintained in accordance with the GASCO Inspection and Corrosion Management Policy requirement. Wherever possible, the requirements of the GASCO CIPs shall be applied. Each site shall maintain an up-to-date register of approved Site-Specific Inspection Procedures and have them recorded in accordance with their respective ISO 9001-2008 Quality Management document system. 2.2.2.6 Associated Procedures related to corrosion management and related subjects are listed in Appendix G. 2.2.2.7 Internal Corrosion Management Procedures for monitoring and controlling internal corrosion are generally covered by NACE RPs, see Appendix B. The following lists company specific procedures and guidelines for a number internal corrosion aspects: 2.2.2.7.1 Internal Corrosion Monitoring a. Refer to Guidelines TT-GU-502 Rev-0 on May 2014 – Corrosion Monitoring Philosophy ①

2.2.2.7.2 Fluid Analysis and Process Monitoring a. Refer to ASTM-D1293 Standard Test Methods for pH in Water b. Refer to ASTM-D1125 Standard Test Methods for Electrical Conductivity and Resistivity of Water c. Refer to ASTM-A515 Standard Specification for Pressure Vessel Plates, Carbon Steel, for Intermediate- and Higher Temperature Service d. Refer to Supplier Recommendations: d.1 HACH

– Testing for iron species

d.2 BDH Chemicals – Testing for chlorides d.3 APHA

– Testing for sulfur species

2.2.2.7.3 Pipeline Maintenance Pigging Refer to GASCO Pipeline division Operation Procedures a. Typical Liquid Hydrocarbon Line Pigging Procedure (Doc # PLO-PR-001) b. Pigging Philosophy (Doc# PLO-PR-019) c. Gas Pipeline Typical Pigging Procedure (Doc # PLO-PR-010)

2.2.2.7.4 Chemical Management Under development

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2.2.2.7.5 Corrosion Inhibition and Chemical Injection As per Licensor Recommendation following feasibility study

2.2.2.7.6 Biocide Treatment As per Supplier (NALCO) recommendations, NALCO 7330 biocide

2.2.2.7.7 Oxygen Scavenger Treatment As per supplier recommendations and allowed limit of Oxygen content

2.2.2.7.8 Material Selection (CS, SS, CRA, etc.) Refer to Appendix 4 of Recommended Practice for Material Selection GCMM/MSRP/AGM(T)001

2.2.2.7.9 Material PMI Refer to DGS 0000-001 Rev01 Positive Material Identification

2.2.2.7.10 Material Traceability Refer to DGS 1300 1901 Traceability of Shop and Field Fabricated Piping Metallurgy

2.2.2.8 External Corrosion Management Procedures External Corrosion Management Procedures to monitor and control external corrosion are given in Appendices A, B. The procedures cover both external corrosion of above ground structures and buried structures, such as pipelines and cover the following topics: 2.2.2.8.1 Cathodic Protection (CP) a.

DGS-1674-001-Rev01

DGS of CP for Plant Facilities

b.

DGS-1674-002-Rev02

DGS of CP for Pipelines

2.2.2.8.2 Coating/Painting a. DGS 6600-010 Rev 1, Painting New Construction. Appendix G, TSC-GU-002 for Maintenance Painting 2.2.2.8.3 Corrosion under Insulation (CUI) Appendix F, TS-TSC-009 Inspection of Corrosion under Insulation

2.3 Description of the Inspection and Corrosion Management Framework The ICMS consists of an Inspection and Corrosion Management Process that is held within a Corrosion Management Framework, as illustrated in Figure 1. All assets fall under the requirements of the

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framework. This framework pulls together the process, and links it to other aspects relevant to AIRMS. The different framework elements that are illustrated in Figure 1 are discussed below.

2.3.1 Policy The ICMS follows the guidelines set by the GASCO Inspection and Corrosion Management Policy, which states that Inspection and Corrosion management must ensure that the design objectives and functionality of the GASCO facilities are maintained for the projected life of these facilities, see GASCO Inspection & Corrosion Management Policy (June 2009).

2.3.2 Context The ICMS is viewed in light of external and internal contexts. The external context relates to an external environment, such as regulatory requirements, i.e. ADNOC Code of Practice on Identification and Integrity Assurance of HSE Critical Equipment and Systems (ADNOC-COPV6-01), financial and technological. The internal context relates to the internal environment, in which GASCO seeks to achieve its objectives. These include: a. Policy b. Organizational structure c. Roles and accountabilities d. Capabilities in terms of resources and knowledge, e. Communication, information systems and flow, and decision making process f. Standards and guidelines

2.3.3 Organization The GASCO Inspection, Corrosion and Metallurgy Department, which is responsible for the development and implementation of the ICMS, falls under the Engineering and Technical Services Division (TE). New organization chart is shown in Appendix I.

2.3.4 Accountability 2.3.4.1 The Head of Department, Corrosion, Inspection and Metallurgy is the owner of the ICMS. The responsibilities of the owner of the ICMS are to:

a. Verify compliance with the ICMS Manual and all its defined requirements b. Review and endorse the overall contents of the ICMS. c. Review and endorse the contents of, and any significant changes to the ICMS. d. Appoint an Inspection and Corrosion Management Administrator. e. Verify technical resources to assure appropriate overall implementation and stewardship of corrosion control and monitoring programs. f. Review and endorse GASCO’s inspection and corrosion management objectives and stewardship plans.

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g. Establish the process to review the status and current issues identified through the ICMS. h. Ensure that all elements and sub-elements of the ICMS are routinely reviewed and updated. i. Conduct an annual assessment of the GASCO inspection and corrosion management programs and ICMS, and report the findings to the GASCO – Engineering Division Manager.

2.3.4.2

2.3.4.3

The Site Inspection Section Heads are administrators of the ICMS. The responsibilities of the administrators of the ICMS are to: a.

Prepare and coordinate the development of the detailed system documentation and implementation plans.

b.

Maintain ICMS element and sub-element documents by ensuring that regular reviews and updates are completed as required.

c.

Coordinate implementation of the ICSM.

The Owner of a GASCO asset is accountable for the inspection and corrosion management of that asset. The asset owner may delegate some, or all, of this responsibility to his Site Managers, providing authority levels are appropriate. The role of the owner is to assure that all aspects of the assets are managed to achieve sound business results, which includes adherence to the ICMS. The responsibilities of the asset owner includes: a.

Review and endorse the overall contents and implementation plans for the asset’s corrosion control and monitoring.

b.

Review and endorse the content of, and any changes to, the inspection and corrosion control/monitoring programs.

c.

Review and approve the status and current issues identified through the Inspection and Corrosion Management programs, including deviations

d.

Assure the cost effectiveness of asset Inspection and Corrosion Management programs

2.3.4.4

Site Inspection Personnel are responsible to execute the inspection program and to ensure that site relevant pressure and structural equipment technical data, historic files and inspection records, are readily available and accessible in GASCO approved formats. Site Inspection Personnel are further responsible for reporting, and ensuring the quality of the inspection and testing data.

2.3.4.5

The Inspection, Corrosion and Metallurgy Department is responsible to provide technical advice and support to the site’s inspection personnel in all related areas of expertise within the overall Inspection and Corrosion field, including but not limited to: a.

RBI methodology and risk-based planning supporting tools, TS-TSC-4-GL-1 (Appendix D);

b.

Welding and welding procedures and specifications, see Appendix H;

c.

NDT and application of the latest NDT technologies and developments, see Appendix F and E;

d.

Fitness-for-Service (FFS) studies, API 597 (Appendix B);

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e.

Metallurgy, Metallurgy selection and Corrosion Risk Assessment (CRAS) studies, TS-TSCRP-QP-12 (Appendix E);

f.

Failure analysis, failure investigations, and Root Cause Analysis (RCA), EPR/AGM(O)/005 (Appendix G)

g.

Cathodic Protection (CP) systems, see NACE CP RPs (Appendix B);

h.

Painting, coating and insulation systems, TSC-GU-002 (Appendix G).

2.3.5 Resources Allocation of appropriate resources to deliver programs, which are consistent with the ICMS, must be ensured. This is accomplished by allocating proper budgets, by setting achievable staffing levels, and by developing and implementing training programs to ensure the right amount and the right competence levels of staffing.

To provide specific detailed requirements in support of the ICMS, a suite of discipline and/or subject related documents, such as listed in Appendices A-F shall be available. These documents contain comprehensive information, mandatory requirements, detailed instructions and advice in order to ensure that the integrity of the static and pressure equipment will not be adversely affected during their service life. A plan to develop Inspection & Corrosion staff competency shall be developed and implemented, see Appendix G - TSC/CDM/01.

2.3.6 Communication The ICMS facilitates internal and external communication and reporting mechanisms associated with the ICMS. The mechanisms are supported by documentation and database management. 2.3.6.1

Internal communication is achieved as follows: a.

Set KPI’s at all levels in order to clarify and achieve common objectives of the ICMS.

b.

Set up communication channels to management and stakeholders

c.

Communicate the ICMS to staffing at all levels via annual on-site and discipline specific workshops.

2.3.6.2 External communication includes the following: Awareness training for contractors and vendors and particular importance is the communication with vendors of inspection and corrosion control equipment, and chemicals to ensure that the services and products provided meet the ICMS requirements.

2.3.7 Process Integration ICMS consists of core process of inspection and corrosion management. This core process is integrated with other management systems in its operating environment and the process to create

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accountabilities, to identify resources, and to provide links to internal and external management systems for assessing and managing degradation risks.

2.3.8 Continuous Improvement Continuous improvement of the ICMS is carried out in accordance with ISO 9001 and is achieved by management audits, which are conducted on different levels. 2.3.8.1 A corporate audit framework under the responsibility of the Internal Audit Department is intended to review and verify the effectiveness of the ICMS as follows: a.

Independent audits are performed by the international shareholders.

b.

Audit findings are recorded and prioritized, and corrective actions are identified with assigned action parties and targeted completion dates.

c.

Best practices and lessons learned are shared with assets and sites as appropriate.

2.3.8.2

Each section of the ICMS process will be systematically audited by the Engineering discipline engineers to ensure detailed compliance by each of the operational sites in accordance with GASCO auditing procedure SVP (T)-TS-QP 06.

2.3.8.3

GASCO has developed a score card system in order to provide a consistent, systematic and high-level overview for ICMS policy compliance levels, for engineering discipline specific activities.

2.3.8.4

Any proposed change to the ICMS requires a formal Management of Change (MoC). The originator of a change should complete MoC documentation, which should be reviewed and endorsed by the Head of Department, Corrosion, Inspection and Metallurgy, who should consult and obtain the advice of subject matter experts in the disciplines as necessary.

2.3.8.5 Verification of Facilities Change processes is the responsibility of the Asset Owner.

2.4 Implementation of Inspection & Corrosion Management Standard From the ICMS, the corrosion assessment and treatment activities are defined via a corrosion control matrix, and managed via the maintenance management system (MMS), such as Maximo. Activities that are carried out to implement the ICMS are defined in the corrosion management process, which defines threat assessment and response activities.

2.5 Risk Based Inspection (RBI):

①

Risk Based Inspection focuses risk assessment on maintaining integrity of static equipment by minimizing the risk of failure associated with applicable corrosion/degradation mechanisms while optimizing inspection activities for all GASCO operating plants. GASCO S-RBI guidelines ( Ref no : TT-PR-005 Rev-2) document has been developed to provide GASCO operational plants with common guidelines to be used for the application, management of change (MOC) and periodic review of the Risk Based Inspection methodology.

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2.5.1 Risk Based Inspection review process is applied to all GASCO operating plants for the following stages: a) New Projects at FEED stage / plants equipment b) Plant change orders (Provided by Projects and Plant) c) Changes in process parameters, such as increase in process fluid characteristics, temperature or flow rates, or where thermal insulation is removed. d) Changes in chemical Corrosion inhibitor injection strategy. e) Plant modifications, additions or removal of plant, including like for like vessels or process pipe change out. f) Changes in corrosion rates which become known either by an inspection campaign or from information from corrosion monitoring equipment. g) After Inspections h) 5 yearly major review processes.

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3.0 INSPECTION AND CORROSION MANAGEMENT PROCESS

The inspection and corrosion management process is the core of the ICMS and is established within the inspection and corrosion management framework. The inspection and corrosion management process is not intended to prescribe process criteria, as these criteria will be specific to each asset. Compliance of the ICSM with GASCO Inspection and Corrosion Management Policy is mandatory. It is stated that the GASCO ICMS policy is to ensure that the design objectives and functionality of the GASCO facilities are maintained for the projected life of these facilities. The inspection and corrosion management process, which consists of three main elements, i.e. Scope and Context, Threat Assessment, and Threat Response, is established within the context of the ICMS framework, see Figure 1. 3.1 Scope and Context 3.1.1 Asset Identification The inspection and corrosion management process that is used for each group of assets varies from asset to asset and depends on the specific corrosion threats that are associated with each in their lifecycle. GASCO operates 4 major gas treatment facilities (Asab, Buhasa, Habshan/Bab, and Ruwais), and approximately 3,000 km of pipelines. The inspection and corrosion management process includes clear procedures and requirements for identifying the assets to which the Inspection & Corrosion management process applies, see Appendices B-G. This also includes the use of asset registers, which are created for each of the major facilities and pipeline networks. 3.1.2 Strategy and Delivery The Inspection & Corrosion management process identifies processes that are associated with developing strategies and/or delivering the strategies. 3.1.3 Integration with Risk and Integrity Management The corrosion management process is integrated with, and complementary to GASCO’s AIRMS framework. ICMS is a supporting element of the major three integrity management systems, i.e. PIMS. ICMS assesses, identifies, analyzes, and treats the corrosion threats to facilities and pipelines, which is the Probability of Failure (PoF) component of the risk. Through this process, the overall risk to the facilities and pipelines will be reduced and by means of the Corporate RAM the identification and reduction of risk is communicated to GASCO Management.

3.2 Degradation Threat Assessment This section discusses how degradation threats such as corrosion are assessed, including the two major steps of threat identification and threat analysis. The purpose of the Degradation Threat Assessment is to assess the static pressure equipment with respect to their degradation threats and to identify options to remove, mitigate or manage the threats. Together with the consequence of failure (CoF), the probability of failure (PoF) determines degradation risk (PoF x CoF), which can be related to the GASCO Corporate risk matrix, see Figure 2. The Corporate risk matrix identifies the degree of tolerance or acceptance of risk and the need to reduce an unacceptable risk to an ALARP level.

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3.2.1 Threat Identification Identification of specific degradation threats is essential for planning and control purpose to ensure that all threats are effectively managed. The purpose of threat identification is to assess the static equipment in relation to the type and severity of the threats. Although degradation threats include all threats (see definition in Section 1.4), corrosion threats are most common. These corrosion threats can be divided into external and internal corrosion and in GASCO NGL Plant they may include, but are not limited to the following corrosion mechanisms: 3.2.1.1 Internal Corrosion 3.2.1.1.1 CO2 corrosion 3.2.1.1.2 H2S corrosion/cracking a. Sulfide stress cracking (SSC) b. Hydrogen induced cracking (HIC) c. Stress oriented hydrogen induced cracking (SOHIC) d. Hydrogen blistering 3.2.1.1.3 O2 corrosion 3.2.1.1.4 Microbiologically influenced corrosion (MIC) 3.2.1.1.5 Erosion corrosion 3.2.1.2 External corrosion 3.2.1.2.1 Atmospheric corrosion 3.2.1.2.2 Soil corrosion 3.2.1.2.3 Galvanic corrosion 3.2.1.2.4 Microbiologically influenced corrosion (MIC) 3.2.1.2.5 Weld and weld root corrosion 3.2.1.2.6 Corrosion of heat affected zones (HAZ) 3.2.1.2.7 Pitting 3.2.1.2.8 Crevice corrosion 3.2.1.2.9 Corrosion under insulation (CUI) 3.2.1.2.10 Stress corrosion cracking (SCC) 3.2.1.2.11 Erosion corrosion 3.2.1.2.12 Corrosion fatigue cracking

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Applicable degradation mechanisms are provided in GASCO’s “Site Specific Corrosion Management Strategy” documents, which identify the degradation mechanisms for each major facility including: a.

A general overview of the process and the assets, including the asset’s Metallurgy.

b.

The applicable damage mechanisms, internal and external corrosion with discussions on:

b.1 The degradation mechanism, b.2 Its major drivers and influencing factors, and b.3 Applicable prevention and mitigation measures. The requirements of the GASCO Common Inspection Procedures shall apply, see Appendix F. Each site shall maintain an up-to date register of approved site-specific inspection procedures, and have them recorded within their respective ISO 9001-2008 Quality Management document system. Mandatory inspection requirements for testing of all HSE-CES pressure equipment are specified in individual written schemes of periodic inspection (WSOPI). Each item of pressure retaining equipment shall be individually registered within Maximo, RBI System and/or IDMS. 3.2.2 Threat Analysis Once corrosion threats have been identified on a system and circuit level, they are analyzed to determine mode, severity, likelihood, and interaction with other threats. The process for determining when a response is necessary is also part of the analysis. As part of the corrosion threat analysis the sensitivity of parameters affecting the corrosion rate, such as CO2 concentration, H2S concentration, temperature, pressure, flow rate, and water content, shall be assessed. Where appropriate flow modeling and corrosion modeling will be used to analyze the corrosion threats. This will allow the identification of those critical parameters which form the basis for establishing the Integrity Operating Windows, and may require closer attention over the asset’s operational life. 3.3 Threat Response Once the threats have been identified, controls can be implemented to manage the severity of these threats to an acceptable level. These controls include Engineering/Design controls, administrative controls, inspections and monitoring. The response to each active corrosion threat present within an asset should be documented in the Site Specific Corrosion Management Strategy. 3.3.1 Selection The corrosion management process addresses and includes procedures describing how responses to threats are selected to ensure that the likelihood of the threat is adequately reduced. The process addresses the manner in which corrosion threats are analyzed to determine their severity, likelihood, interaction and damage modes. If the corrosion threat cannot be eliminated, which is usually achieved through a design change (see GASCO DGS), and then the corrosion threat has to be either mitigated or managed. Mitigation can be achieved through the use of corrosion resistant Metallurgy (CRA/SS), application of paints or coatings, cathodic protection (CP), and chemical inhibition, see Site Specific Corrosion Management documents. Corrosion mitigation is assured through corrosion monitoring and inspection. 3.3.2 Implementation The implementation of a threat response is divided into external corrosion and internal corrosion. Typical corrosion threats in GASCO NLG plants are listed in Section 3.2.1. Appendix B lists International Standards and Recommended Practices dealing with corrosion threat response. GASCO specific documents dealing with corrosion control are listed in Appendix G. 3.3.2.1 External corrosion threats of above ground structures inside facilities are generally managed with paints or coatings, and visual inspection and NDT schedules. Of specific concern is the threat of corrosion under

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insulation (CUI), where water accumulates under insulation and creates a generally difficult-to-detect location where severe corrosion can occur. 3.3.2.2 External corrosion of buried in-plant structures is managed with a combination of compatible coatings and cathodic protection (CP). Impressed current cathodic protection (ICCP) or sacrificial anode cathodic protection is used. ICCP is the common form of CP, although at specific locations (hot spots) additional sacrificial anode CP may be applied. 3.3.2.3 Scheduled in-line inspection (ILI) and CP surveys are used to assess the condition of the pipeline at time intervals to be verified by the Engineering specialist. Follow-up dig programs are used to further monitor and assess coating damage and corrosion. If a pipeline is unpiggable, alternative assessment methods can be used, such as Direct Assessment (ECDA/ICDA). 3.3.2.4 Internal corrosion of in-plant vessels, piping and cross country pipelines is managed with a combination of internal inspection, and/or chemical treatment and monitoring. The following aspects of an internal corrosion mitigation plan must be considered: a. The suitability of chemical programs against production streams and contaminants b. The corrosion inhibitor chemical performance, type of injection (batch or continuous), and injection rates. c. Environmental impact of inhibition chemicals. d. Chemical injection hardware and their location e. Type of corrosion monitors and their location with respect to the chemical injection point. f. Corrosion probe location and position 3.3.2.5 Internal corrosion of cross country pipelines can also be assessed and managed by one of the following methods: a.

ILI

b.

Direct Assessment (ECDA/ICDA)

3.3.2.6 Following threat assessment using appropriate methods and tools, repair or replacement is implemented per GASCO OPR/OPL/PLM/026 (Appendix G). 3.3.3 Management Procedures for the ongoing management of the implemented treatment measures are part of the corrosion management process. These procedures include the following measures: 3.3.3.1 Internal corrosion 3.3.3.1.1 Inspection a. Visual b. NDT c. ILI

3.3.3.1.2 Corrosion inhibition 3.3.3.1.3 Repair

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a. Temporary repairs b. Permanent repairs References to the relevant International Recommended Practices and GASCO procedures are given in Appendix B and G, respectively. 3.4 Pressure Equipment Protection This section of the document specifies the requirements for the GASCO Pressure Equipment Program (PEP), for the safe and reliable service of pressure vessels and pressure relief devices. The requirements apply to pressure vessels in the scope of the ASME Boiler and Pressure Vessel (B&PV) Code (all sections) and to all pressure relief devices that protect systems or components from overpressure. The Pressure Equipment Protection (PEP) program shall consist of four (4) activities: a.

Verification,

b.

Registration,

c.

Fitness-for-Service, and

d.

Repair

3.4.1 Verification 3.4.1.1 Pressure Vessels 3.4.1.1.1 All pressure vessels in the scope of the ASME B&PV code must comply with the applicable ASME B&PV code section, and be stamped accordingly. 3.4.1.1.2 Pressure vessels must have a verification record, numbered and filed in GASCO’s IDMS. The pressure vessel verification record shall include: a. the record cover sheet, b. the design report (vendor or site-generated design calculation showing code compliance), and c. the ASME data report (U-1 data report for ASME VII Div. 1 vessels). 3.4.1.1.3 If an existing vessel was originally procured without a code stamp (no data report, no design calculation), its verification record must include calculation of the required minimum wall thickness. 3.4.1.1.4 Pressure vessel verifications records must be approved by the Engineering Specialist prior to operational testing and operation. 3.4.1.2 Pre-commissioning Inspection

①

The Project Group shall ensure that plant inspection personnel are actively involved in monitoring the contractors works during the pre-commissioning and commissioning activities such as snag / punch listing, initial thickness survey of piping and equipment, baseline intelligent pig survey of the pipeline, baseline RBI, cathodic protection systems, DCVG and CIPS surveys. A copy of the final documents pertaining to these activities shall be handed over to the Inspection Section.

3.4.1.3 Warranty Inspection:

①

Warranty inspection is required to ensure that following an initial period of service, the overall design, construction and materials are satisfactory and any defects observed are thoroughly investigated.

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Initial measurements are taken to form the basis for assessment of deterioration. This is normally carried out after 12-24 months of service and before final acceptance of the facility. Warranty Inspection of equipment shall be done as appropriates based on RBI and process requirements. Along with Operations Inspection Group, Project Engineering Div. shall actively participate to coordinate the remedial actions with the EPC Contractors. Any lessons learnt shall be incorporated in the GASCO’s DGS specifications for future projects.

3.4.1.4 Subsequent Inspections:

①

The frequency of inspection of equipment must be based on risk based inspection methodology by identifying the rate of deterioration and the risk of failure. If RBI has still not established for any plant or part of the plant, the plant inspection section head shall propose the inspection frequency, which shall be endorsed by Technical Manager. Optimization of inspection frequencies shall be done through S-RBI as soon as possible.

3.4.1.5 Inspection Activity Variation Control:

①

The RBI Inspection frequency is generated to take the “Next Due Date” of Inspection activity as “Target Start date”, which is the ‘Expected Date’ when individual Inspections or tests, are due to be carried out. Compliance Band: For planning purposes, some flexibility is required with regard to the scheduling of activity execution; however strict control must be exercised over any ‘delay’ to the ‘Expected Date’, in order to maintain the Technical Integrity of the Plant or equipment concerned. To ensure an effective control over Integrity Critical Inspection activities such flexibility (Maximum Allowable Deviation) shall be predetermined for different categories of equipment according to their criticality levels and functions. The following table shows the ‘Maximum Allowable Deviation’ (called Compliance Band) for Integrity Critical activities, however the Compliance Band shall not exceed any deadlines stipulated in this standard for any of these activities

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Table: Compliance Band Ranges (% of Inspection Interval) S.No

Discipline

Inspection Activity Description

Compliance Band

1

Inspection

Vessel, On-Plot Piping, Relief Valve Inspections, Tank and

10%

Corrosion Coupon Retrieval. 2

Inspection

Major Support Structures

15%

3

Inspection

Scraper Launcher and Receiver Trap and Pipeline Valve

15%

Maintenance 4

Inspection

Intelligent Pigging of Pipelines and Coating Surveys on

15%

buried Pipelines. 5

Inspection

Cathodic Protection System Maintenance or Monitoring

15%

6

Inspection

Lifting Equipment Inspections

10 %

Control of variance:

①

a) Variance Control Any period of time after the ‘Compliance Band’ Range is known as the ‘Variance Control Band’. For an Inspection activities are to be rescheduled into the ‘Variance Control Band’, the alternatives, risks and consequences shall be assessed by the relevant specialist together with his department head (Head of Technical Services Department) after which the VP plant operations authorization shall be obtained, in writing (use Inspection Activity Variation Control Form-A as given in Appendix-M). The Variance Control Band allows for a further delay to the ‘Expected Date’ on the same basis used to determine the ‘Compliance Band’, which must never exceed 20% of the service interval, (up to a maximum delay of 12 months).

b) Excess Variance Control To exceed the ‘Variance Control Band’ the VP plant operations authorization shall be obtained again, in writing (use Inspection Activity Excess Variation Control Form-B, as given in Appendix-M). In this case the VP plant operations must also advise the SVP-Operations. However, the revised Variance Date shall not exceed the original Expected Date by more than a total of two 20% of service interval periods of time up to a maximum of 24 months, (i.e., two x10% of a 5 year service interval).

Roles and Responsibilities: Inspection discipline Section Head, for the particular equipment type is responsible for the application of Inspection Activity Deviation Policy. His duties include: - Raise Variance Control Form - Raise Excess Variance Control Form - Keep auditable records on delay authorization

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- Provide monthly performance indicators on number of authorizations. He is also responsible for the technical evaluation of any proposed delay of Inspection activities. The relevant specialist should consider all aspects of fitness for purpose of the item, its known rate of deterioration, the estimated time remaining before a failure may occur, any practical alternatives, e.g. use of non- intrusive inspection, and record these before submitting a decision to support or reject the proposed request.

Compliance Band & Deviation control Band Diagram

Max. Delay from last Inspection date = 10% of Inspection interval (Max up to 6 months)

Additional Max. Delays 10 % of Inspection interval (Max. up to 6 months)

VARIANCE

EXCESS VARIANCE

Range for scheduling Activity

Authorized by site VP-OP

Compliance Band (20% of Inspection Interval)

Variance Control Band (10% of INSP Interval)

Authorized by SVP-OP

Excess Variance Control Band (10% of INSP control) Deviation Control

t=Inspection Interval Last RBI Inspection date

Raise the Technical concession Next RBI Inspection date Last Expected Date

MAXIMUM VARIATION=24 MONTHS (i.e. 2X10% of 5 years Inspection interval)

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3.4.1.6 Pressure Relief Devices 3.4.1.6.1 The ASME Code dictates the necessity of overpressure protection. The pressure protection requirements of other codes and national regulations must also be considered in the selection of pressure relief devices. 3.4.1.6.2 All pressure relief devices with a set pressure at or above 15 psig must comply with ASME B&PV Code, unless approved otherwise by the Engineering Specialist. 3.4.1.6.3 All pressure relief devices must have a verification record, numbers and filed in MMS, which establishes their adequacy. 3.4.1.6.4 Pressure relief device verification records must be approved by the Engineering Specialist. 3.4.1.6.5 All in-place testing of pressure relief devices must follow a written procedure, approved by the Engineering Specialist prior to testing. 3.4.1.6.6 PSV inspection frequency: Inspection frequency shall be as per Maximo calculations formula.

①

Next Inspection date = Test Date + (21-Total Score)* A+B

S.No 1 2

3

4

PSV TESTING RESULTS The valve is not opening up to 1.05 the set pressure. The valve is leaking and /or is opening below 0.90 of the set pressure. The valve is opening within 0.90 to 1.05 of set pressure. The valve is passing two consecutive tests and ‘previous score + current score =