Engineering Procedure

SAEP-384 18 January 2016

In-Service Inspection Requirements for RTR Pipe
Document Responsibility: Inspection Engineering Standards Committee

Contents
1 Scope..................................................................... 2
2 Purpose.................................................................. 2
3 Conflicts and Deviations......................................... 3
4 Applicable Documents............................................ 3
5 Definitions, Abbreviations and Acronyms............... 5
6 Instructions............................................................. 7
7 Responsibilities..................................................... 14

Appendix A - Number of Initial CMLs Criteria…….….. 17

Appendix B - Low Pressure RTR Pipe CML
Monitoring Frequency and Revalidation........ 18
Appendix C - High Pressure Threaded
Joint RTR Pipeline Revalidation…………….. 19
Appendix D - NDT Technique Selection Criteria……. 20
Appendix E - RTR Pipe In-Service
Inspection Workflow....................................... 22
Detailed Table of Contents.......................................... 23

Previous Issue: 13 October 2013 Next Planned Update: 13 October 2018

Revised paragraphs are indicated in the right margin Page 1 of 23
Primary contact: Lodhi, Zeeshan Farooq (lodhizf) on +966-3-8804518

Copyright©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

1 Scope

1.1 This Saudi Aramco Engineering Procedure (SAEP-384) defines the minimum
requirements for in-service inspection of nonmetallic Reinforced Thermosetting
Resin (RTR) piping and pipelines.

1.2 This procedure applies only to RTR piping and pipelines in water and oily
hydrocarbon service in Saudi Aramco operating facilities.

1.3 RTR piping which are on or a part of equipment owned and operated by
Contractors within Saudi Aramco Operating Units shall be tested and inspected
in accordance with this Procedure.

1.4 Exclusions

The following are excluded from this procedure:

1.4.1 RTR piping in Saudi Aramco operations which are covered by other
recognized International Standards and regulations with requirements
and test intervals more stringent than those specified in this procedure.

1.4.2 RTR piping in Saudi Aramco operations where the Operating

Department (Proponent) Manager approves the applicable requirements
as more stringent than those specified in this procedure.

1.4.3 Buried in-plant gravity flow RTR piping systems are excluded from the
requirements for CML establishment for existing facilities.

2 Purpose

2.1 To document requirements for improving RTR piping and pipelines

performance in-service and assuring that they are used within the operating
tolerances set by the material manufacturer and design.

2.2 To ensure roles and responsibilities for RTR piping and pipeline monitoring,
testing and inspection are clearly outlined and auditable.

2.3 To ensure RTR pipe remains in good physical condition and provide safe and
reliable operation against unexpected leaks, damage or service related failures.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

3 Conflicts and Deviations

3.1 Conflicts

Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAES's), Materials System Specifications (SAMSS's),
Standard Drawings (SASD's), or industry standards, codes, and forms shall be
resolved in writing according to the requirements of SAEP-302.

3.2 Deviations

Direct all requests to deviate from this procedure in writing to the Company or
Buyer Representative, who shall follow the internal company procedure SAEP-302.

4 Applicable Documents

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-122 Project Records
SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-308 Operations Inspection Unit Reviews
SAEP-309 Inspection of Community and Operations Support
Facilities
SAEP-1135 On-Stream Inspection Administration

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-135 On Stream Inspection Requirements
SAES-B-067 Safety Identification and Safety Colors
SAES-L-610 Nonmetallic Piping in Oily Water Services
SAES-L-620 Design of Nonmetallic Piping in Hydrocarbon and
Water Injection Systems
SAES-L-650 Construction of Nonmetallic Piping in Hydrocarbon
and Water Injection Systems

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

SAES-S-020 Oily Water Drainage Systems

SAES-S-040 Saudi Aramco Water Systems
SAES-S-060 Saudi Aramco Plumbing Code
SAES-S-070 Installation of Utility Piping Systems

Saudi Aramco Materials System Specifications

01-SAMSS-029 RTR (Fiberglass) Sewer Pipe and Fittings for
Gravity Flow
01-SAMSS-034 RTR (Fiberglass) Pressure Pipe and Fittings
01-SAMSS-042 Reinforced Thermoset Resin (RTR) Pipe and
Fittings in Water and Hydrocarbon Services

4.2 Industry Codes and Standards

American Petroleum Institute

API RP 570 Piping Inspection Code: In-service Inspection,
Rating, Repair, and Alteration of Piping Systems
API RP 574 Inspection Practices for Piping System Components

American Society of Mechanical Engineers/Boiler and Pressure Vessel Code

ASME SEC V Nondestructive Examination
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquids and
Slurries
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME B31.9 Building Services Piping

American Society for Testing and Materials

ASTM D2563 Practice for Classifying Visual Defects in Glass-
Reinforced Plastic Laminate Parts
ASTM D3567 Practice for Determining Dimensions of
“Fiberglass” (Glass-Fiber-Reinforced
Thermosetting Resin) Pipe and Fittings

American Water Works Association

AWWA C950 Fiberglass Pressure Pipe
AWWA M45 Fiberglass Pipe Design

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

Fiberglass Tank and Pipe Institute

FTPI RP 2007-1 Recommended Practice for the In-Service Inspections
of Aboveground Atmospheric Fiberglass
Reinforced Plastic (FRP) Tanks and Vessels

5 Definitions, Abbreviations and Acronyms

5.1 Abbreviations and Acronyms

EIS Equipment Inspection Schedule
FRP Fiberglass Reinforced Plastic
GRE Glass Reinforced Epoxy
GRV Glass Reinforced Vinylester
GRP Glass Reinforced Polyester
RTR Reinforced Thermosetting Resin
SCC Standards Committee Chairman

5.2 Definitions

Acoustic Emission (AE): Technique that can be used for detecting surface
cracks, trans-laminar crack, flange crack, pit and delamination. AE determines
crack growth in a qualitative manner. It is noteworthy that since composite
material is anisotropic, the damping is larger than in metals. AE uses stress
waves as it depends upon the signal originating from within RTR. AE is a
passive method since the RTR itself generates the sounds requires for the
inspection. Wave is generated in materials as a result of sudden, inelastic and
local change in stress level accompanied with inelastic deformation.
To simulate acoustic emission, RTR needs to be subjected to external load.
Field testing AE process is also available. There are several AE procedures
available for fiber reinforced plastic vessel and tanks which can be applied for
the RTR system with modification.

Acoustography: This is a simple and efficient ultrasonic (UT) imaging process.

It provides real-time, full-field ultrasonic imaging process where an acousto-
optic area detector (AO detector) is employed to convert the ultrasound into a
visual image in near real time. Acoustic images can be formed by simple
shadow casting (analogous to radiography) or with acoustic lenses (analogous to
photography or videography). In principle, ultrasound is passed through the
nonmetallic test component where it is absorbed, reflected, and scattered by
material structure and any anomalies therein. The projection image of the
material structure and anomalies is created by the ultrasound as it exits the test
component. This projection image is converted into a corresponding visual
image by the AO detector in near real time. A video camera and frame grabber

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

can be used to digitize the image for computer storage and image enhancement.

Acoustography is a higher speed method than conventional UT inspection

method. It can scan from one side of the sample and the technique can be used
in transmission and reflection mode. Acoustography can be used to detect the
surface crack, trans-laminar crack, impact damage and delamination. However,
it cannot obtain information on depth of features detected in the specimen.

Condition Monitoring Location (CML): Designated area in nonmetallic

piping or pipeline where periodic examinations are conducted. CML may
contain one or more examination points.

Examination Point (EP): An evaluation point, measurement point, or

inspection point within the CML where condition assessment is performed.

Examiner: A specifically trained, certified and authorized person who

performs specific NDT on RTR piping or pipeline. The examiner may also
evaluate the results of the examination if they are authorized to do so by the
Operations Inspection Unit Supervisor.

In-Service Inspection: All inspection activities associated with RTR piping

and pipeline or other assets after it has been initially placed in service including
RTR piping systems in turnaround, under maintenance or not currently in
operation due to an outage of the process.
Exception:

In-service inspection does not include RTR piping systems that are still under
construction or in transport to the site prior to being placed in service or RTR
systems that have been retired.

Microwaves: A new technique for dielectric material inspection. A defect in

RTR can be detected by backscattering of microwaves. The defect will be viewed
as a media with different dielectric constant with different rate and phase from the
adjacent material. The system can detect external impact, delaminations, changes
in thickness, etc.

Nondestructive Examination (NDT): Any of the examination methods

described in Appendix designed to evaluate the condition of a RTR piping or
pipeline system without causing a destructive effect. More details on NDT can
be found in ASME SEC V, Nondestructive Examination, ASME B31.3,
Chemical Plant and Petroleum Refinery Piping, ASME B31.4, Liquid
Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous
Ammonia, and Alcohols, ASME B31.8, Gas Transmission and Distribution
Piping Systems, ASME B31.9, Building Services Piping, and NBIC NB 23,
National Board Pressure Vessel and Boiler Inspection Code.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

Shearography: A Speckle pattern shearing interferometry which is a coherent-

optical measuring and testing method and similar to holographic interferometry.
It is a non-contact optical NDT technique which can be used to identify both
flaws and defects on the surface and sub-surface in nonmetallic material.
This technique can be used to detect surface crack, trans-laminar crack, impact
damage and delamination. The technique works on glass fiber, carbon fiber,
laminates, metals, etc. Shearography works as an optical video strain gauge
which can locate strain caused by defects while loaded. In application, load can
be applied in the form of pressure, thermal or vibration. For RTR pipes and
pipelines, internal pressure of RTR can be used as a mean to load the pipe.
Since for RTR pipe no external load is required hence there is no possibility of
damage being incurred by the excitation.

Thermography: Determines the flaw when heat is introduced on the surface of

the composite and by monitoring the heat flow. Thermography can be used to
detect impact damage, delamination and erosion on the RTR pipe.
Thermography is a non-contacting and non-invasive method. It can inspect a
large area in a single snapshot. The heating can be applied to RTR by optical,
air flux or specific heating blanket used for composite repair. Among
thermographic techniques, thermal pulse thermography is the most commonly
used technique. As soon as the heat is applied, the RTR’s temperature will
change due to thermal diffusion, radiation and convection. The normal pattern
of heat flow is interrupted as it met with the flaw and flaw/defects appear as
areas of different temperature. Anisotrpy of the composite reduces the strength
of the themography to detect the flaws. Thermography sometimes cannot detect
the cracks aligned parallel to the direction of heat flow as well.

Visual Inspection (VE): VE is the simplest and fastest method of finding

flaws in materials. VE shall be performed prior to using any other NDT Test.
Results may vary depending on the capability of the inspector and illumination.
Optical aids such as magnifying glass through endoscopes and boroscopes can be
used to detect flaws and improve the quality of the detection, if normal eyesight is
not sufficient for flaw detection. Most of the surface flaws such as burn, chip,
surface crack, pit, UV damage, wear scratch, weeping and erosion can be detected
or inspected by VE method. However, visual inspection will not be able to detect
any sub-surface flaws which did not show any surface disturbance.

6 Instructions

6.1 Program Establishment

The following OSI program is established for adhesive bonded RTR piping and
pipeline system up to 500 psi pressure rated pipe. OSI program for High
pressure threaded joint RTR pipeline will be discussed in Section 6.8.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

6.1.1 Circuit and CMLs Assignment

Review Piping and Instrument Drawings (P&IDs) and select piping

circuits such that the smallest number of circuits can be created,
representing the entire damage mechanisms anticipated. On P&IDs trace
with a different color to show the monitored zone and locations. Areas
which have high potential for failure (i.e., joints, wear scratch, minor
repaired zone) shall be flagged to help facilitate establishing the OSI
frequency. On each piping circuit establish the initial number of CMLs
using guidelines provided in Appendix A.

The following factors should be considered when assigning CMLs:

a) Service conditions –pressure, temperature, flow velocity, fluid
composition, particulates in fluid
b) Type of RTR material
c) Plant history
d) Manufacturer's recommendations for condition monitoring
e) Industry experience with similar RTR system in service
f) Local comparable service experience
g) Use of conservative estimation
h) Accessibility of the CML for monitoring
i) Maximum Saudi Aramco intervals (see below)
j) Engineering evaluation such as Risk Based Inspection (RBI) study
recommendation
k) Associated Plant T&I schedules dictated by SAEP-20 “Equipment
Inspection Schedule”
l) Compare with similar requirements in SAES-A-135 and
SAEP-1135 (where applicable) and ensure benefits associated
with RTR system installation are considered.
m) All Loss Prevention (LPD) Bulletin and recommendations relating
to Oily Water Systems and Oily Water Sewer lines operation and
inspection shall still apply.
n) All MSAERs relating to safety, operation and maintenance of Oily
Water Sewer systems shall still apply.
Commentary Note:

In the event of failure and excavation occurs, CLMs must be installed

according to the requirements in the SAEP for new projects.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

6.1.2 Data Collection at CML

Each CML shall be monitored by collecting data which shall include

both visual and NDT data as specified in Appendices B and D.
When indexed to points in isometric piping precisely, the same CML can
be monitored repeatedly. This ensures that the inspection is done
accurately on the defined CML consistently and the representative data
gathered can be trended.

6.1.3 Scheduling

After CMLs have been identified, baseline data shall be collected as soon
as possible. Thereafter, the frequency of monitoring will be based on
criteria set in this SAEP.

6.1.4 Data Analysis and CML Optimization

a) Gathered inspection data shall be evaluated within 14 days from
date of collection.
b) Data analysis must include determination of the system reliability
based on the original design criteria and the next inspection date
based on criteria set in this SAEP.
c) All data collected shall be uploaded into System Assurance and
Inspection of Facilities (SAIF) program. The periodical analysis
and reporting should be conducted using SAIF.
d) When one full cycle of NDT inspection frequency requirement in
Appendix B has been completed, the initial number of CMLs shall
be reviewed and optimized if necessary. A formal report shall be
issued to department management for reviewing conclusion and the
recommendation.
e) Optimization shall include reviewed of all operation, inspection
and maintenance history including test inspection results, leak
history, change of fluid condition, low flow or intermittent
operations, etc.

6.1.5 Reporting

Quarterly reporting of all completed survey and data analysis

conclusions shall be made by OIU Supervisor in a formal report to
department management.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

6.1.6 Training
a) All personnel associated with condition monitoring of RTR piping
and pipeline systems shall receive basic manufacturer’s material
based training on the type of system installed and demonstrate
understanding of the requirements of this SAEP.
b) The training and certification of the personnel associated with
condition monitoring shall be evaluated at a frequency of 3 years
by OIU supervisor.
c) RTR NDT Examiners shall be certified and be approved to perform
the work by the Operations Inspection Unit Supervisor.

6.2 Condition Monitoring Locations

6.2.1 Condition Monitoring Locations shall be clearly marked in the drawing

and at the location to allow for repeated evaluation.

6.2.2 All buried RTR pipeline shall have test holes established as CMLs for
effective condition monitoring except as indicated in the scope 1.4.3.
a) Minimum number of test holes shall be established at every 10% of
the length of the pipeline or 1 kilometer whichever is lesser.
b) Additional test holes may be requested by the area inspector based
on the inspection results.
c) The size of test holes should be a minimum of 3 meters and a
maximum of 15 meters. In construction of test holes, the area
30 cm or more from the RTR pipeline shall be excavated by hand
to avoid mechanical damage of the pipeline.
d) The data point at each test hole should be assigned by the department
corrosion engineer in the On-Stream Inspection (OSI) drawings.
e) Global Positioning System (GPS) shall be utilized to allocate data
points.
f) Type of inspections applicable to the CML shall be indicated in the
OSI drawing showing visual and the NDT technique.
g) To ensure that data are collected from the same location the test
hole area including the pipe shall be properly marked.

6.2.3 Bends and elbows shall have a minimum of 10% or one (1) of the total
number marked as CML, whichever is greater.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

6.2.4 Joints of all types shall have a minimum of 10% or two (2) of the total
number marked as CML, whichever is greater.

6.2.5 Nozzles shall have a minimum of 10% or one (1) of the total number
marked as CML, whichever is greater.

6.3 Inspection Interval

6.3.1 All RTR piping and pipeline systems shall have an approved EIS based
on the inspection intervals specified in Appendices B and C.

6.3.2 EIS shall be created by the OIU supervisor and the model shall be
included in SAIF.

6.3.3 NDT evaluation shall be conducted at the CML monitoring frequency in

Appendix B or half the calculated remaining life using the original
design basis, whichever is lower.

6.3.4 Random visual inspection of at least 10% of the sections of nonmetallic

systems is required on an annual basis as in Appendix B.

6.3.5 Condition monitoring that is not conducted by their due dates as

documented in the nonmetallic system EIS shall be considered overdue.
Escalation of overdue items shall follow the requirements of SAEP-20.

6.4 Nondestructive Examination and Testing Techniques

6.4.1 Examination and Inspection Scheduling shall be according to the

requirements of Appendix D.
Commentary Note:

“Currently, NDT is limited to visual examination. Evaluation of other NDT

techniques shall be coordinated with Inspection Technology Unit of
Inspection Department.”

6.4.2 Prior to any NDT assessment, initial visual inspection shall be conducted
to evaluate the overall condition of the nonmetallic system at the CML.
The NDT Technician should look for leaks, scale, obstruction, and any
obvious damage before starting the NDT evaluation.

6.5 Revalidation

6.5.1 Re-validation Requirement

Low pressure RTR Pipe systems shall be re-validated by hydrostatic

testing at 110% of their operating pressure every fifteen (15) years as
mandated in Appendix B.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

6.5.2 Re-validation Procedure

A “Re-validation Test Package” developed by the area operations

engineer shall be approved as specified in concurrence and approval
below, prior to any re-validation activity and it shall minimally include:
a) Re-validation Procedure
b) Operating conditions of the RTR piping or pipeline system.
c) Re-validation test conditions based on the original design standard.
d) Leakage testing instructions and criteria.
e) Assure any provided manufacturer's test procedure is adequate for
the system as long as the requirements of this SAEP are met.
f) Roles and responsibilities are clearly defined.
d) Personnel safety precautions such as personal protection equipment
(PPE), discharge considerations, and other precautions determined
to be necessary shall be stated.
e) Description of the necessary tools and equipment that must be
present before the test begins.
f) Concurrence and approval of “Re-validation Test Package”:
● Plant Operations Engineering Unit Supervisor (Concur)
● Plant Inspection Unit Supervisor (Concur)
● Area Loss Prevention Superintendent (Concur)
● Superintendent of Engineering (Concur)
● Superintendent of Operations (Concur)
● Department Manager (Approval)

6.6 Quality Assurance Manual

6.6.1 All RTR piping and pipeline systems in Saudi Aramco operations shall
have a Quality Assurance Manual prepared by the maintenance division
and approved by the Maintenance Division head and the local Inspection
Unit Supervisor.

6.6.2 The manual shall contain:

a) A detailed list of handling, repair or replacement recommendations.
b) A list of non-conformancies which impact the RTR pipeline system
integrity in addition to any applicable listed in this SAEP.
c) Work procedures used to repair, inspect and test installed RTR

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
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Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

pipeline systems including location of CMLs.

d) Recommended controls for all repair activities and requirements
relating to manufacturer’s and this SAEP’s recommendations.
e) RTR pipelines can fail for several reasons. Impact damage and
debonding on the joints are the key factors of failure for RTR pipe in
the field. Besides these, fabrication and installation defects and
operating condition have been found as the prime reasons for RTR
pipe failure.
f) Gravity flow test procedure and interval.
g) Bend joints and risers require inspection procedure approved.

6.6.3 The QA Manual shall be reviewed and revised, every three years.

6.6.4 The purpose of the Manual is to have a central reference source that
describes or references the nonmetallic manufacturer’s recommended
handling, shop work methods, repair procedure, testing procedure, and
personnel qualifications. The Manual shall assure that quality
maintenance standards will be continuous even with personnel turnover.

6.7 RTR Piping and Pipeline In-Service Inspection Program Reviews

6.7.1 All RTR piping and pipeline in-service inspection programs shall be
assessed and audited annually by the Supervisor, Operations Inspection
Unit or delegate.

6.7.2 Inspection Department shall review the program audit reports including
conclusions and recommendations during the OIU assessment in
accordance with SAEP-308.

6.8 High Pressure Threaded Joint RTR Pipeline

6.8.1 Monitor pressure drop in high pressure threaded joint RTR pipelines on a
weekly basis.

6.8.2 Significant drop of pressure (~300 psi) excluding the effect of temperature
and pressure cycling shall trigger further investigation to be initiated by
the plant corrosion engineer jointly with the area Operations/Plant
Engineer to eliminate likelihood of pipe or joint damage.

6.8.3 Perform hydrotest to revalidate high pressure threaded joint RTR

pipelines every five (5) years as outlined in Appendix C.
Commentary Notes:

High pressure RTR pipelines are generally buried and carrying hydrocarbon

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
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Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

with or without H2S at higher pressure. The pipe spools are connected with
threaded mechanical joint which provides higher integrity to the system.
Since the RTR pipe will not be corroded over time the joint is only point of
concern and any breach in joint or in the pipe should be noticed through
pressure drop.

7 Responsibilities

7.1 Manager, Operating Facility

7.1.1 Approves assigned NDT Examiner for RTR piping and pipeline systems.

7.1.2 Final approval of internal department revalidation procedure for RTR

piping and pipeline systems developed according to manufacturer’s
recommendation and the original design basis.

7.2 Operations/Plant Engineer

7.2.1 Develops RTR piping and pipeline revalidation procedure.

7.2.2 Proposes RTR piping and pipeline system inspection interval optimization
based on calculated remaining life using original system design basis.

7.2.3 Review and make recommendations on any process changes that will
have an impact on the in-service performance of RTR piping and
pipeline systems.

7.3 Department Corrosion Engineer

7.3.1 Assigns all CMLs.

7.3.2 Reviews, verifies data and comments on RTR piping and pipeline system
revalidation procedure for the OIU Supervisor.

7.3.3 Investigates RTR piping and pipeline system failures and makes
appropriate recommendations to OIU Supervisor.

7.3.4 Reviews the RTR piping and pipeline systems in-service (OSI) report.

7.3.5 Identifies all high potential damage areas in the RTR piping and pipeline
system for monitoring focus and CML allocation.

7.3.6 Marks all areas of potential mechanical damage or leaks in the P&ID’s.

7.3.7 Reviews any process changes that will have an impact on the OSI program.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
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Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

7.4 Operations: Foreman

7.4.1 Reviews, verifies data and comments on RTR piping and pipeline system
revalidation procedure for the OIU Supervisor.

7.4.2 Ensures markings and identification of CMLs in field are accurate.

7.4.3 Approves revalidation testing by signing and writing “approved for

Re-validation Testing” next to the Work Order prior to start of any field
activity.

7.5 Operations: Superintendent

7.5.1 Concurs revalidation procedure.

7.5.2 Approves MOC, if applicable.

7.6 Maintenance Foreman

7.6.1 Develops and maintains approved copy non-metallic systems QA Manual.

7.6.2 Ensures adequate trained and certified installers are available for RTR
piping and pipeline systems repair work.

7.7 Operations Inspection Unit Supervisor

7.7.1 Responsible for establishing in-service inspection program for RTR

piping and pipeline systems.

7.7.2 Reviews and maintains a fully approved copy RTR piping and pipeline
systems QA Manual required according to this SAEP.

7.7.3 Verifies that adequate trained and certified installers are available for
RTR piping and pipeline systems repair work.

7.7.4 Ensures adequate trained and certified inspectors and NDT technicians
are available for RTR piping and pipeline systems repair work.
The certified inspector shall have at least attended a 3 day long course at
the product manufacturer facility.

7.7.5 Liaises with Inspection Department and CSD on all activities relating to
nonconformance of RTR piping and pipeline systems in operating
organizations.

7.8 OSI Administrator

7.8.1 Plans and execute the OSI Program.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
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Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

7.8.2 Issues the required OSI progress report and overdue report to the unit
supervisor.

7.8.3 Coordinates NDT action between area inspector and NDT Technician as
required.

7.8.4 Issue reports to Inspector and Corrosion Engineer.

7.9 Field Supervisor

7.9.1 Assures all the critical RTR piping and pipeline are monitored under OSI
program.

7.9.2 Reviews the OSI report with the responsible area inspector and advise
any other necessary actions required.

7.9.3 Ensure the OSI program data is reviewed, analyzed and added to SAIF.

7.10 Area Inspector

7.10.1 Conducts baseline survey to ensure pipes and joints are leak and damage
free.

7.10.2 Prepares isometrics drawings for all the critical RTR piping and pipeline
including joint locations.

7.10.3 Issues quarterly report to the unit supervisor.

7.11 Project Management Team (PMT) or Construction Contractor

7.11.1 Assigns initial CMLs in projects prior MCC at all critical locations
(i.e., joints, wear scratch, minor repaired zone), and conduct baseline
survey to determine any flaws and defects outlined in Appendix A.

7.11.2 Assures turnover of baseline data and CML location marked drawings to
proponent department at MCC finalization.

Revision Summary
13 October 2013 New Saudi Aramco Engineering Procedure.
18 January 2016 Minor revision to incorporate the modification recommended during waiver approval.
Revealing RTR piping by excavation is considered impractical to do visual inspection for Oily
Water System (OWS) gravity flow system as per attached Appendices A, B and C.

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Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

Appendix A - Number of Initial CMLs Criteria for Low Pressure RTR Pipe

Appendix A.1 - Area Aboveground

Low Pressure CML Quantity

Asset Category Remarks
(Minimum)

Pipelines, Aboveground 10% of length or 100 meters Whichever is lesser

Piping, Aboveground 10% of length or 50 meters Whichever is lesser

Nozzles, Aboveground 10% of all or 1 Whichever is greater

Fittings, Aboveground 10% of all or 1 Whichever is greater

Elbows, Aboveground 10% of all or 1 Whichever is greater

Joints, Aboveground 10% of all or 2 Whichever is greater

Appendix A.2 – Buried

Low Pressure CML Quantity

Asset Category Remarks
(Minimum)

Pipelines, Buried 10% of length or 1 kilometer Whichever is lesser

Piping, Buried

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

Appendix B - Low Pressure RTR Pipe CML Monitoring Frequency and Revalidation

Visual Visual Revalidation

Asset Category Examination, Examination, NDT Hydrotest at 110%
10% Coverage 100% Coverage Operating Pressure

Pipelines, Buried Annual 5 years 10 years 15 years

Pipelines, Aboveground Annual 5 years 10 years 15 years

Piping Annual 5 years 10 years 15 years

Equipment Annual 5 years 10 years 15 years

Nozzles Annual 5 years 10 years 15 years

Fittings Annual 5 years 10 years 15 years

Elbows Annual 5 years 5 years 15 years

Joints Annual 5 years 5 years 15 years

Piping, Buried

Gravity flow buried in

plant piping

Closed drain buried in

plant piping

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Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 13 October 2018 In-Service Inspection Requirements for RTR Pipe

Appendix C - High Pressure Threaded Joint RTR Pipeline Revalidation

Revalidation Hydrotest
Asset Category
at 110% Operating Pressure

Pipelines, Buried In every 5 years

Page 19 of 23
Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 25 September 2018 In-Service Inspection Requirements for RTR Pipe

Appendix D - NDT Technique Selection Criteria

NDT Methods with Ranking

Defect Description Acceptance Criteria
Visual
Thermal decomposition evidenced by Acceptable if burn is not in the
Burn 1
surface distortion or discoloration structural layer
A small piece broken from surface or Area of damage must be less than
Chip 1
edge; if fiber is broken then it is crack 10x10 mm (⅜x⅜ in)
Sharp crack that reaches the reinforcing
Surface Crack Acceptable as-is or re-coat 2
fibers
Crack which is oriented transverse to the
Trans-laminar Crack None permitted
laminated plane
Flange Crack Overstressed bolted joints None permitted 2
Fine hairline cracks at or under the Acceptable up to 25 mm
Crazing or microcracking 1
surface of the component (1 in) in length
Rupture of the component with complete
penetration of the laminate. Majority of
Fracture None permitted 1
fibers broken, Visible as lighter colored
area of inter-laminar separation
Discoloration and possible bubble
Areas larger than 10 mm
Impact Damage reaching the reinforcement-with or 3
(⅜ in) diameter are not permitted
without broken fibers
Brittleness
Acceptance criteria to be
Material aging Strength/modulus changes 1
determined
Softening/swelling
Changes in dimensions resulting from
Dimensional Change Acceptable criteria to be determined 1
loads, deflections imposed on system
Small crater in the inner surface of a Diameter of the pits to be less than
Pit/Pin Hole laminate, with its width approximately of 0.8 mm (1/32 in) and depth to be 1
the same order of magnitude as its depth less than the thickness of the liner
Discoloration and increased roughness
UV Induced Fiber Blooming None permitted 1
of the pipe surface

Page 20 of 23
Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 25 September 2018 In-Service Inspection Requirements for RTR Pipe

NDT Methods with Ranking

Defect Description Acceptance Criteria
Visual
Shallow mark caused by improper
Area of damage shall not affect the
handling, storage and/or transportation.
Wear Scratch fibers and shall not be larger than 1
If reinforcement fibers are broken, the
10x10 mm (⅜x⅜ in)
damage is considered a crack
Area where plies within RTR laminate Acceptance criteria to be
Delamination
become separated determined
For water systems: Possibly
Acceptable. Monitoring (leak rate)
Minor liquid penetration through the
Weeping and criticality assessment required. 1
laminate during pressure testing
No fiber damage/ or fracture is
acceptable
Weak bonds between adhesive and RTR Acceptance criteria to be
De-bonds and kissing bonds 3
adherent determined
Barely Visible Impact Damage-Under
Acceptance criteria to be
BVID impact most composites do not show
determined
much external evidence of damage
Internal or external localized material
Erosion None permitted 1
removal by abrasive erosion or cavitation

Page 21 of 23
Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 25 September 2018 In-Service Inspection Requirements for RTR Pipe

Appendix E - RTR Pipe In-Service Inspection Workflow

Develop EIS for All RTR Piping/Pipelines

LP HP
RTR RTR
LP or
HP
RTR?

LP RTR - Assign Initial CMLs

Perform 10% Annual VE

Complete 100% VE within 5 yrs HP RTR - Revalidate every 5 yrs

(Appendix C)

Perform NDE every 10 yrs

Revalidate every 15 yrs

(Appendix B)

Document Results and update Inspection Plan

Page 22 of 23
Document Responsibility: Inspection Engineering Standards Committee SAEP-384
Issue Date: 18 January 2016
Next Planned Update: 25 September 2018 In-Service Inspection Requirements for RTR Pipe

Detailed Table of Contents

1 Scope………………………………………………………………………………………... 2
2 Purpose……………………………………………………………………………………... 2
3 Conflicts and Deviations………………………….……………………………………... 3
3.1 Waivers…………………………………………………………………………..…... 3
3.2 Deviations…………………………………………………………………................ 3
4 Applicable Documents………………………………………………………………….... 3
4.1 Saudi Aramco References…………………………………………..……………... 3
4.2 Industry Codes and Standards…………………………………………………….. 4
5 Definitions, Abbreviations and Acronyms…………………………………….……... 5
5.1 Abbreviations and Acronyms…………………………………..…………………... 5
5.2 Definitions…………………………………………………………………................ 5
6 Instructions…………………………………………………………………...................... 7
6.1 Program Establishment…………………………………………………………….. 7
6.2 Condition Monitoring Locations…………………………………………………… 10
6.3 Inspection Interval………………………………………………………………….. 11
6.4 Nondestructive Examination and Testing Techniques……………………….... 11
6.6 Quality Assurance Manual………………………………………………………... 12
6.7 RTR Piping and Pipeline In-Service Inspection Program Reviews…………… 13
6.8 High Pressure Threaded Joint RTR Pipeline……………………………………. 13
7 Responsibilities………………………………………………………………………….. 14
7.1 Manager, Operating Facility…………………..…………………………………... 14
7.2 Operations/Plant Engineer………………………………………………………... 14
7.3 Department Corrosion Engineer……………………..…………………………... 14
7.4 Operations: Foreman………………………….…………………………………... 15
7.5 Operations: Superintendent……………………..………………………………... 15
7.6 Maintenance Foreman…………………………………………..………….……... 15
7.7 Operations Inspection Unit Supervisor…………………………………………... 15
7.8 OSI Administrator…………………………………………………………………... 15
7.9 Field Supervisor…………………………………………………………………..... 16
7.10 Area Inspector…………………………………………………………………….... 16
7.11 Project Management Team (PMT) or Construction Contractor……………….. 16
Appendix A - Number of Initial CMLs Criteria for Low Pressure RTR Pipe…………. 17
Appendix B - Low Pressure RTR Pipe CML Monitoring Frequency and Revalidation… 18
Appendix C - High Pressure Threaded Joint RTR Pipeline Revalidation……………. 19
Appendix D - NDT Technique Selection Criteria…………………………………………. 20
Appendix E - RTR Pipe In-Service Inspection Workflow……………………………….. 22

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