Best Practice

SABP-M-001 Inspection Guidelines of Offshore Structures Document Responsibility: Offshore Structures Standards Committee 11 May 2008

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 Introduction.................................................. References................................................... General......................................................... Definitions..................................................... Inspection Procedure.................................... 2 3 3 4 5

Table 1.0 - Inspection Guide.............................. 9 Table 2.0 - Recommended Periodic Inspection Intervals......................... 14
Developed by: Ala A. Al-Sharif Civil Engineering Unit/M&CED Consulting Services Department

Previous Issue: New Next Planned Update: TBD Page 1 of 14 Primary contact: Sharif, Alaeddin Abdul Raouf on 966-3-8745321
CopyrightSaudi Aramco 2008. All rights reserved.

Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Introduction 1.1 Purpose This Practice establishes guidelines and recommended procedures for the inspection of Saudi Aramco offshore facilities above and below water to ensure that all facilities are adequately inspected on a regular basis as a general good engineering and safety practice and while in operation, including a general inspection of the jacket platform after installation and prior to commissioning of the platform. 1.2 Scope This guideline formulates an integrated, general and non-prescriptive engineering approach to be utilized while maintaining, evaluating and re-qualifying existing Saudi Aramco offshore facilities/platforms to ensure an acceptable level of reliability. This guideline is based on the Recommended Practice for Planning, Designing and Constructing of Fixed Offshore Platforms according to the American Petroleum Institute (API) and the Petroleum and Gas industries Fixed steel offshore structures by International Organization for Standardization (ISO). 1.3 Disclaimer The material in this Best Practices document provides the most correct and accurate design guidelines available to Saudi Aramco which complies with international industry practices. This material is being provided for the general guidance and benefit of the Designer. Use of the Best Practices in designing projects for Saudi Aramco, however, does not relieve the Designer from his responsibility to verify the accuracy of any information presented or from his contractual liability to provide safe and sound designs that conform to Mandatory Saudi Aramco Engineering Requirements. Use of the information or material contained herein is no guarantee that the resulting product will satisfy the applicable requirements of any project. Saudi Aramco assumes no responsibility or liability whatsoever for any reliance on the information presented herein or for designs prepared by Designers in accordance with the Best Practices. Use of the Best Practices by Designers is intended solely for, and shall be strictly limited to, Saudi Aramco projects. Saudi Aramco is a registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2002. 1.4 Conflicts with Mandatory Standards In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco Engineering Requirement, the Mandatory Saudi Aramco Engineering Requirement shall govern.
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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

References This Best Practice is based on the latest edition of the references below, unless otherwise noted. 2.1 Industry Codes and Standards American Petroleum Institute (API) API RP 2A Recommended Practice for Planning, Designing and Constructing of Fixed Offshore Platforms

International Organization for Standardization (ISO) ISO 19902: 2007(E) Petroleum and natural gas industries Fixed steel offshore structures

General 3.1 The outlined procedure in sec. 5.0 is recommended to serve as the basis for above and underwater inspection program. This is done to monitor the adequacy of the corrosion protection system, check structural defects, accidental damages and evaluate the general condition of the facility. These inspections will help to safeguard human lives and properties, protect the environment and qualify the facilities for their intended service or extend their operating life. Three types of inspection are recommended (See Paragraph 5.3): Type I Type II Type III 3.3 3.4 : : : General above water visual inspection. General underwater visual inspection. Detailed underwater inspection.

3.2

A quick guide for inspection is outlined in Table 1.0, and the recommended inspection intervals are shown in Table 2.0. Any findings during the inspection that may be of concern to the structural integrity of a facility, which may affect the safety of the personnel and the environment, should be referred to Consulting Services (CSD) and Inspection Departments (ID) for assessment.

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Definitions
Manned Platform: A platform which is continuously occupied by persons living on the platform (e.g., living quarter platforms). Other Structures: Structures other than manned and unmanned platforms (dolphins, piers, trestles, free standing conductors, etc.). Splash Zone: Area of a structure that is frequently wetted due to waves and tidal variations. Unmanned Platform: A platform which may be occupied by persons but not living on the platform (other GOSP-platform, loading platform, metering platform, etc.). AWS: American Welding Society. ANSI: American National Standards Institute. API: American Petroleum Institute. ASME: American Society of Mechanical Engineers. CP: Cathodic Protection. DFIR: Design, Fabrication and Installation Records. ISO: International Organization for Standardization. NDT: Non-Destructive Testing. ROV: Remote Operated Vehicles. SCOUR: Removal of seabed soils caused by currents and waves. SCR: Structure Condition Records

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Inspection Procedure The following procedure should be used as a guideline in performing inspection surveys (above & underwater) for offshore facilities: 5.1 Planning and Personnel Qualification Surveys should be planned and carried out at regular intervals (see Paragraph 5.4) by personnel who are proficient in Non-Destructive Testing (NDT) methods, possess survey experience and have demonstrated ability and experience by passing practical tests, or be qualified to the appropriate codes, such as AWS (D1.1-2002), ASME/ANSI or equivalent. Also, the observations by the facility operating and maintenance personnel should be incorporated in their survey reports. Adequate illustrations of the structures are essential for carrying out accurate inspection. This includes providing structural drawings for above and below water and clear location of items to be inspected, see also Paragraph 5.5. Underwater survey should be conducted by skilled and qualified divers or/ and by means of Remote Operated Vehicles (ROV) under the supervision of qualified personnel or by divers. The NDT operator working underwater should be required to possess the following qualifications: a. b. 5.2 Certification in NDT methods. Extensive diving experience and a minimum of two (2) years of experience in certified NDT work underwater.

Inspection Methods In selection of the inspection method a number of parameters should be considered, including the joint geometry, applied stress, material thickness and location. An approved procedure for each inspection method should be developed for each job application using one or more of the following NDT methods: 5.2.1 5.2.2 Visual Penetrant Technique (PT) This is a useful method in detecting surface discontinuities such as cracks, porosity, etc. 5.2.3 Magnetic Particle Technique (MPT) This method is useful for discontinuities that are open to the surface or which are slightly subsurface.
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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

5.2.4

Radiographic Technique (RT) This method is useful for determining buried or through thickness discontinuities.

5.2.5

Ultrasonic Technique (UT) This method is also useful for determining buried or through thickness discontinuities.

5.3

Inspection Types 5.3.1 Type I General Above Water Visual Inspection This inspection consists of general visual inspection of the structure above water to determine: a. The effectiveness of the corrosion protection system, coating deterioration, damaged areas or excessive corrosion especially in the splash zone. Indications of overloading, missing or damaged members.

b.

If above water damage is detected and visual inspection is not sufficient, measurement and NDT should be used to determine the extent of the damage. Sufficient cleaning, such abrasive blasting, shall be carried out to remove heavy corrosion scale. Special attention should be paid to platform legs and members at the splash zone. If this inspection indicates possible underwater damage, a Type II inspection should be conducted. 5.3.2 Type II General Underwater Visual Inspection This inspection consists of general underwater visual inspection by ROV under the supervision of qualified personnel or by divers with head mounted cameras to detect the presence of any of the followings: a. b. c. d. e. f. Metal separation due to fatigue damage at high stress area (e.g., tubular joints of primary and secondary members, can sections, etc.). Excessive marine growth. Member damage, i.e., dented, , flooded, ruptured/ missing members due to accident or environmental overload. Seabed subsidence, settlements, scours, debris, gas/ oil seeps, etc. Construction deficiencies. Excessive anode depletion and corrosion due to faulty CP system.
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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Detection of significant structural damage during Type II inspection should be subjected to further evaluation, and Type III inspection should be conducted as soon as possible. 5.3.3 Type III Detailed Underwater Inspection At this stage some or all of the following activities are carried out: - Marine growth measurement, - Scour size measurement, - Wall thickness measurement, - CP measurement and measurement of anodes diameter. Pre-selected underwater areas of known or suspected damage based on structural analysis or of engineering concerns are subjected to thorough inspection and evaluation. These areas should be sufficiently cleaned of marine growth to allow accurate visual inspection, quantitative measurements and accurate NDT for crack detection, e.g., using MPT. Table 1.0 should serve as a guideline for the specific items that should be addressed during the actual inspection. 5.4 Inspection Frequency 5.4.1 Periodic Inspection The first annual inspection should be carried out within 12 months after the date of commissioning the offshore facility/ platform. Table 2.0 shows the recommended periodic inspection intervals which should not be exceeded unless longer intervals can be justified. Justification for changing the interval should be supported by the appropriate documents and retained by the facility proponent. In such cases, the following factors should be taken into account: a. b. c. e. d. Original design criteria. Present design criteria, service history and structural reserve strength. Facility/ platform location and the criticality of the platform to other operations. Facility classification as Manned, Unmanned platforms or free standing conductors. Consequence of failure to human life, property, the environment, and/or conservation of natural resources.
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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

f. 5.4.2

Well types (sour gas, high pressure, etc.).

Non-periodic Inspection A Type I inspection should be conducted after exposure to excessive environmental loading. A Type II inspection should be conducted upon completion of the initial drilling or workover, after severe accidental loading (boat collision, etc.), or one year after completion of a major underwater structural repair. A Type III inspection should be conducted if the structure was subjected to abnormal loadings that may affect the structural members below water levels, e.g., accidental boat impact.

5.5

Record Keeping, Recommendations and Final Report 5.5.1 All relevant records of the structure history and the inspection reports should be retained by the facility proponent for the life of the facility. This should contain video tapes, photographs, measurements, damage descriptions, divers reports, etc. These records should be documented as the followings: a. Design, Fabrication and Installation Records (DFIR) This describes the structure as installed based on documentation of the design (D), fabrication (F), and installation (I) phases. This should contain a general description of the structure, design premises and calculations, description of materials, pile driving records, etc. b. Structure Condition Records (SCR) This serves as a data bank on the current condition of the structure. It contains records of any exceptional event that takes place during the structure service life. It also should summarize the findings from each inspection and address any areas/ items of concern which might be significant in subsequent inspections. 5.5.2 The evaluation of the platform condition and recommendations shall be based on the collected data from the above sources. The final report shall contain all the necessary information of the structure until the next inspection.

11 May 2008

Revision Summary New Saudi Aramco Best Practice.

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Table 1.0 Inspection Guide

(s) = special reference to steel structures (c) = special reference to concrete structures

ITEM CODE

Significant Areas of Inspection

Possible Defects

Possible Reason/s for Defects

Possible Consequence of Defects - Progressive development of defects due to re-distribution of force - Accelerated deterioration - Accelerated deterioration, corrosion, etc. - Reduction in load bearing capacity - leakage

General inspection of structure

General or major defects that may impair the safety and integrity

- Static or cyclic overloading - Collision, dropped objects - Material deterioration

Area of Repair

- Failure of repair material - Rebar corrosion (c) - Cracking - Weld failure (s)

- Poor workmanship - Unsuitable materials or repair procedure - Shrinkage (c) - unforeseen stress concentrations

Area of inferior construction

- localized material deterioration - Corrosion - Deformations

- Poor workmanship or method of construction - Poor concrete quality (c) - Dense Reinforcement (c) - Design unsuitable

- Accelerated deterioration, corrosion, etc. - Reduction in load bearing capacity leakage

Area of high stress

- Cracking - Corrosion - Spalling of concrete cover (c) - Signs of material yielding

- Structure geometry - Unexpected stress concentrations - Force redistribution

Progressive development of: - Cracking - Corrosion - Force redistribution - Leakage

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD Table 1.0 continued

SABP-M-001 Inspection Guidelines of Offshore Structures

ITEM CODE

Significant Areas of Inspection

Possible Defects

Possible Reason/s for Defects

Possible Consequence of Defects

Area of cyclic stress

- Signs of material fatigue - Cracking and spalling - Corrosion - Local structural failure

- Cyclic loading mainly from waves - Vibration

Progressive development of: - Structural failure - Deformation - Cracking - Corrosion - Spalling

Welded joint with steel thickness > 50mm (s)

- Lamination - Cracks

- Local material defect - Cyclic loading - Poor workmanship

- Local and progressive structural failure

Cut-outs/ penetrations (s)

- Cracking - Deformation of hole

- Overload - Unexpected stress concentration

- Local cracking - Progressive structural failure

Bolted connection (s) Clamps (s)

- Loose or missing bolts - Corrosion - Deformations

- Poor workmanship - Non-secured nuts - Impact loads - Overload

- Loss of structural integrity - Large deformations

Structural members in compression

- Signs of member buckling, i.e., excessive deformations

- Overload - Material creep deformation (c)

- Structural failure of member

Structure foundation (piles, anti-scour system)

- Scouring of seabed - Failure of pile/jacket connections (s) - Seabed subsidence - Settlement - Signs of piping in soil

- Waves and current effects - Poor workmanship or design of anti-scour system - Overload - Emptying reservoir

- Excessive deformation in piles (s) - Differential and total settlement - Reduction in factor of safety for foundation - Problems with connected risers, pipelines and conductors due to displacements - Reduced air gap

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD Table 1.0 continued

SABP-M-001 Inspection Guidelines of Offshore Structures

ITEM CODE

Significant Areas of Inspection

Possible Defects

Possible Reason/s for Defects

Possible Consequence of Defects

Corrosion protection system (anodes, impressed current, inhibitors etc.) (s)

- Missing or eroded anodes - Defective anode cables - Defect in inhibitor system - Marine growth on anodes

- Unforeseen current drainage - Inefficient anodes - Malfunction of inhibitor system

- General or local corrosion

Areas for potential measurement (selected points, reference points, reference electrodes) (s)

- Insufficient polarization of steel or sacrificial anodes

- Local or general under capacity in current density from anodes - Missing or eroded anodes - Inadequate CP

- General or local corrosion

Areas for material thickness measurement (s)

- Reduction in material thickness

- Erosion/ corrosion Internally and externally - Abrasion

- Reduction in load bearing capacity

Signs of corrosion on: Areas with signs of corrosion - Steel jacket and deck Structures (s) - Steel gratings (s) - steel parts embedded in concrete (c)

- Malfunction of corrosion protection system (Refer to K and L) - Poor quality of concrete (c) - Stress concentrations - Fatigue - Defective coatings

- Material deterioration - Reduction in material thickness - Reduction in load bearing capacity - Spalling of concrete (c) - Initiate cracking in welds (s)

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD Table 1.0 continued

SABP-M-001 Inspection Guidelines of Offshore Structures

ITEM CODE

Significant Areas of Inspection

Possible Defects

Possible Reason/s for Defects

Possible Consequence of Defects

Concrete joints: - Leakage - Spalling - Corrosion of reinforcement Steel welds: - Cracks - Corrosion

Construction joints (welds, construction joints)

- Poor workmanship in cleaning of joints and compaction of concrete - Poor workmanship or design - Weld hardening - Inherent defects

- Accelerated leakage, leaching or corrosion - Propagation of cracks - Accelerated corrosion

Splash zone of structure

- Corrosion - Deterioration of material and coatings - Signs of mechanical damage - Monel sheeting

- Corrosive/ erosive environment with wetting/ drying cycles - Mechanical damage due to uncontrolled maneuvering of ships/ boats

- Accelerated corrosion/erosion - Spalling of concrete (c) - Reduction in load bearing capacity

Area of mechanical damage (e.g., from abrasion, collision)

- Spalling of concrete (c) - Abrasion on concrete and steel - Buckles and dents in Steel structure - Corrosion

- Abrasion due to anchor wires, dumped objects, etc. - Collision by floating objects, falling or dumped objects, fishing equipment, etc. - Waves and current

- Corrosion - Reduction in load bearing capacity

Embedded steel parts in concrete (c)

- Corrosion of steel and connected reinforcement - Spalling of concrete

- Failure of coating, inadequate cathodic protection - Steel parts in direct contact with reinforcement

- Corrosion of reinforcement - Failure of embedded steel parts.

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Table 1.0 continued

ITEM CODE

Significant Areas of Inspection

Possible Defects

Possible Reason/s for Defects

Possible Consequence of Defects

Coatings (s)

- Coating defects - Spalling - Cracks - Deterioration - Puncture - Adhesion failure

- Poor workmanship during application of coating - Mechanical damage - Chemical deteriorations

- Localized or general failure of coating - Accelerated corrosion and deterioration of coated material

Connection deck/ substructure (c)

- Cracking/ spalling - Corrosion - General failure of connection

- Inherent areas of inferior quality from Construction structure geometry - stress concentrations - Failures in structure or foundation leading to changes in mass and/or stiffness - Changes in foundation behavior

- Gradual failure of connection

Instrumentation

- Marked changes in trends for results, e.g., response, pore pressures, settlements - Reduced material thickness - Cracks in material - Localized corrosion attack and pitting

- Not applicable (defect to be confirmed by visual inspection)

Areas suspect to internal corrosion (s)

- Corrosivity of internal milieu

- Reduced load bearing capacity - Propagation of cracks

Areas of marine growth

- Corrosion related to Marine growth - Increase in structure geometry and mass

- Favorable environment

- Increase wave forces on structure - Overloading on horizontal structural members (s) - Change in response, due to mass increase (s)

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Document Responsibility: Offshore Structures Issue Date: 11 May 2008 Next Planned Update: TBD

SABP-M-001 Inspection Guidelines of Offshore Structures

Table 2.0 Recommended Periodic Inspection Intervals

Inspection Type I Manned Platforms Unmanned Platforms Other Structures 1 yr. 1 yr. 3 yr. II 3 thru 5 yrs. 5 thru 10 yrs. 7 thru 10 yrs. III 6 thru 10 yrs. 11 thru 15 yrs. 15 thru 20 yrs.

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