AUDIT FOR INSPECTION OF INDUSTRIES PIPING SYSTEM IN

THE ROYAL COMMISION PIPELINES CORRIDORS

1) OBJECTIVE
2) SCOPE OF AUDIT
3) DATA FROM ENGINEERING OR INSPECTION DEPT/PIPELINE
CORRIDORS USER
3.1PROCEDURES, STANDARDS AND CODES
3.2PIPELINE DESIGN DATA
3.3PIPELINE INSPECTION DATA
3.4PIPELINE MAITENANCE DATA
3.5ENVIROMENTAL DATA
3.6 Pipe sleepers and Structural support Data
3.7 Details of Pressure gauge and Temperature gauge
4) ANALYSIS
4.1PIPELINE CODES AND OPERATIONAL COMPARISON
5) REPORTS
6) ACTIONS
7) COMPLIANCE AND NCR
8) RISK ANALYSIS,PROTECTION,INSPECTION & MAITENANCE
 1) OBJECTIVE

• The main objective is to engage the SSE for AUDIT and inspections for the activities of the
Industries/Contractor.

• In service Inspections accordance with the “Guidelines for Inspection of In-service Industries
piping systems in the Royal Commission Pipeline Corridors”.

2) SCOPE OF AUDIT

Auditing all Industries piping system that are located in the Royal Commission Pipeline Corridors in
yanbu. An audit is a simple procedure to identify operational and design non-compliances. It consists
of two basic audits:

1. Audit of pipeline design versus design code.

2. Audit of pipeline operation versus pipeline code and company procedures.

3) DATA FROM ENGINEERING OR INSPECTION DEPT/PIPELINE CORRIDORS USER

Gather data from pipeline corridors user (this is the most important part of the process),

3.1-Codes and standards

1. API 570 Piping inspection code: In-service Inspection, Rating, Repair, and Alteration of piping
systems.
2. API RP 574 – Inspection of piping system components
3. Royal commission Engineering Manual, section 11.48
4. ASME B 31.3. Process piping
5. API RP 578 – Material verification of new and Existing piping systems
6. API RP 750 –Management of process Hazards
7. API 598 – Valve Inspection and Testing

3.2- Pipeline inspection data

Pipe line inspection History, NDT report (TML-UTG Report) if any special NDT report (ECT,
Intelligent pigs) CUI report. Pipeline design records, Pressure test records.

3.3-Pipeline maintenance data

Pipelines are surveyed, maintained and monitored according to a code previous surveys and
surveillance, any Modification records is required.

3.4-Design data

Pipeline basic design parameters, and a complete pipeline route, Operational pressure records,
viii. Pipeline inspection and maintenance records. Verification of design parameters for the whole
pipeline following example

1) Pipeline number
2) Identification color coding and marking
3) Pipeline route map and P&ID
4) Operation parameters – operating pressure and pressure fluctuations, operating
temperature.
5) Pipeline test records
 START PRE-AUDIT (Before
AUDIT (Audit team
starting Audit. Audit
visited to industry cross
team prepare for audit
check all corridors
plan and inform to pipeline QA/QC
industry audit date and documents.
time)

Engineering Dept or inspection Codes & Inspection Data (All

Dept (corridor users
responsible to show all audit
related document as per RC
guidelines.)
Code/Operation
al Comparison –
API, ASME and RC
Guide .
Procedures –
(corridors user shod
be follow all
update version
API, ASME and RC
guide line)
Analysis (All pipeline data’s
collect and compare
industries acceptable
codes and standards)
inspection report easy to
access and clearly noted
all the readings of CML )
Maintenance Data (corridors
pipeline CML inspection
time shuttle, injection point
and vale inspection status
gauge calibration status.

Design data (All corridors

pipeline data sheet and P&ID
COMPLIANCE REPORT (All the TML shod be clear)
(Audit team reading compare to the
report to the RC original pipe thickness
Coordinator Audit and then calculate Environment data (QA/QC
findings and remaining life, remaining document should be clear
document corrosion allowance. If atmospheric condition and
accepted or Non there is Non-conformance pipeline operating
conformity and rise report NCR temperature and pressure)
rise NCR T to
INDUSTRY)
No Yes

Audit coordinator notifies ACTION (Audit team rise the NCR

concerned industry forward original copy of audit report &
satisfactory completion of NCR to Audit coordinator & copy to
audit industry.

Industry completes NCR forward to NO Audit coordinator sends

Audit coordinator within number reminders to the
of days as per RC guid line concerned industry
 Yes

Industry completes the NCR complaint

END forward to RC audit coordinator and audit
coordinator notifies concerned industry
on NCR close out.

6) Details of inline components – ex Traps, strainers.

7) Details of insulation and support

4) ANALYSIS

All the pipeline data review and compare to the sectional code and operational comparison.

5) REPORT

All the pipeline data review and compare to the sectional code and Royal commission Engineering
manual, complete the audit checklist and audit report. Summarizing the audit findings issue the
audit report to concerned industry and forward to the audit coordinator.

6) ACTION

The data are analysed and verified, and checked against code and company requirements. Non-
compliances are highlighted and reported to the operator for action.

7) COMPLIANCE AND NCR

Non-fulfillment of specified requirements of the Guidelines for inspection of In-service industries

piping system in the royal commission pipelines corridors substantiated by objective evidence
(Inspection of a line not carried out within the specified frequency).

8) RISK A8NALYSIS, PROTECTION, INSPECTION & MAITENANCE

Review the all Database of Pipeline, Route and Plant Identify all Hazards, Estimate Failure
PROBABILITY, Estimate Failure CONSEQUENCES and Calculate Risk and Recommendation to Pipeline
corridor users industries.
 CORRIDORS PIPING – CHECK LIST
NAME OF COMPANY Date of
Inspection
Line No.

Operating Pressure Operating Temperature (Deg.

(Kg/cm2) C)
Service Length
Dia of pipe line In Use from

Date of previous inspection Inspection Shutdown/ On-stream/ Breakdown

Type
Past History

External condition Bare/ Insulated/ Underground/ Coated

External paint condition Satisfactory/ Needs repair

Condition of support Resting / shoe supports: Satisfactory/ Needs repair

Anchor Supports: Satisfactory/ Needs repair
Guide supports: Satisfactory/ Needs repair
Condition of pipe sleepers / structures: Satisfactory/ Needs repair

Earthing condition Satisfactory/ Needs repair

Condition underneath Grass /Plant_________

Water/Mud_____________
Steam leak________________
Oil_________________
Not visible_______________

Thickness survey Minimum Thickness at bend________________________

Minimum Thickness at pipe_________________________

Vegetation growth Yes/ No

Condition under the culvert Satisfactory/ Needs repair

Condition of Low point Satisfactory/ Needs repair

Drains
High vent points Satisfactory/ Needs repair
Downstream of valves,
orifices

Piping externally patch Yes/ No/ Not Rquired

repaired
Repair/Replacement jobs
carried out

Reason of Thinning/ Leak/ Vibration/ External corrosion/ Impingement/ Accident/ Fire

repair/replacement

Hydro test/ Pneumatic test Kg/cm2g Date of Hydrotest/ Pneumatic

carried out at test
Remarks
(This shall include any other special observation as well as the details of repairs/renewals carried out)

Name/ signature of Audit

Inspection Engineer.
 AUDIT PUNCH LIST
S.NO DESCRIPTION YES NO N/A REMARKS
1 On-stream inspection report available and
regularly up dated
2 Overdue of Piping inspections
3 Minimum alert thickness highlighted in the report
4 Minimum required thickness mention in the data
5 Dead leg location clearly Highlighted in drawing
6 Mixing point location in the process piping
mention in drawing
7 Limit of the corridors piping mention in
drawing(OSBL to Corridors)
8 If piping material "SS” positive material
identification PMI report available
9 If piping weld joints carried out any special heat
treatment like post weld heat treatment
PWHT report available
10 Any piping system retired from service available
in corridors – if yes , details available
11 In corridors piping any Repairs, Alterations, and
Rerating of Piping Systems and temporary repairs
carried out – full details and all NDT report
available
12 Piping failure and leak report
13 Review of previous inspection report – conform
to previous and future inspection time schedule.

AS PER API-570 Recommended Maximum Inspection Intervals

Type of Circuit Thickness Measurements(UTG-CML) Visual External
Class 1 5 years 5 years
Class 2 10 years 5 years
Class 3 10 years 10 years
Class 4 Optional Optional
Injection points 3 years By class
Soil to Air Interfaces ----- By class

Notes:-

CLASS 1

1) Flammable services that can auto-refrigerate and lead to brittle fracture.

2) Hydrogen sulfide (greater than 3 % weight) in a gaseous stream
3) Anhydrous hydrogen chloride
 4) Hydrofluoric acid.
5) Flammable services operating above their auto-ignition temperature
CLASS 2

1) on-site hydrocarbons that will slowly vaporize during release such as those operating below
The boiling point but above the flash point
2) on-site hydrogen, fuel gas, and natural gas
3) on-site strong acids and caustics

CLASS 3

1) on-site hydrocarbons that will not significantly vaporize during release such as those
Operating below the flash point
2) off-site distillate and product lines to and from storage and loading
3) tank farm piping
4) off-site acids and caustics
5) off-site hydrogen, fuel gas and natural gas
6) Other lower risk hydrocarbon piping

CLASS 4

1) Steam and steam condensate

2) Air
3) Nitrogen
4) Water, including boiler feed water or stripped sour water
5) Lube oil, seal oil
6) Plumbing and sewers

External Inspection Checklist for Process Piping

Inspected by Status:

a) Leaks.
1) Process.
2) Steam tracing.
3) Existing clamps.

b) Misalignment.
1) Piping misalignment/restricted movement.
2) Expansion joint misalignment.

c) Vibration.
1) Excessive overhung weight.
2) Inadequate support.
3) Thin, small-bore, or alloy piping.
4) Threaded connections.
5) Loose supports causing metal wear.
d) Supports.
1) Shoes off support.
2) Hanger distortion or breakage.
3) Bottomed-out springs.
4) Brace distortion/breakage.
5) Loose brackets.
6) Slide plates/rollers.
7) Counterbalance condition