Previous Issue: New Next Planned Update: 1 February 2008 Page 1 of 21 Primary contact: Nasser M. Balhareth on 874-5018
Inspection Procedure 00-SAIP-71 31 January 2005 Plant Inspection Index
Document Responsibility: Inspection Department
Saudi Aramco DeskTop Standards Table of Contents 1 Scope............................................................. 2 2 References..................................................... 2 3 Objectives....................................................... 3 4 Responsibilities.............................................. 3 5 Scoring Process............................................. 4 Attachment I Sample PII Summary Report.... 6 Attachment II Sample PII Entry Sheet.... 7 Attachment III Sample PII Chart......... 21
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 2 of 21
1 Scope
This SAIP is to provide guidelines for Saudi Aramco Plant Inspection Units (PIUs) and the Inspection Department Engineering Unit (IEU) to periodically conduct scoring of the PIU performance and submit the results to IEU for semi-annual reporting to plant management. Plant inspection index (PII) is to cover performance of all inspection activities as per the listed seventeen (17) measures in the attachment.
2 References
Saudi Aramco Engineering Procedures
SAEP-20 Equipment Inspection Schedule SAEP-308 Operations Inspection Unit Reviews SAEP-309 Inspection of Community and Operations Support Facilities SAEP-316 Performance Qualification of Coating Personnel SAEP-317 Testing and Inspection (T&I) of Shell and Tube Heat Exchangers SAEP-318 Pressure Relief Valve Program Authorization for Installation,
Deletion and Changes SAEP-319 Relief Valves Routine Test, Inspection, Quality Assurance and
Regulation SAEP-321 Performance Qualification Testing and Certification of Saudi
Aramco Welders SAEP-322 Performance Qualification Testing and Certification of Saudi
Aramco Brazers SAEP-325 Inspection Requirements for Pressurized Equipment SAEP-333 Cathodic Protection Monitoring SAEP-343 Risk-Based Assessment for In-Plant Static Equipment SAEP-1135 On-Stream Inspection Administration SAEP-1140 Qualification of Saudi Aramco NDT Personnel SAEP-1142 Qualification of Non-Saudi Aramco NDT Personnel
Saudi Aramco Inspection Procedures
00-SAIP-06 Pressure Test Requirements 00-SAIP-07 Positive Material Identification Requirements 00-SAIP-12 Equipment Deficiency Reports
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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00-SAIP-51 Electrical Inspection 00-SAIP-72 Inspection Involvement in Management of Change 00-SAIP-73 Inspection Manning Determination Guidelines 00-SAIP-74 Corrosion under Insulation Inspection 00-SAIP-75 External Inspection 00-SAIP-76 Worksheet Control & Tracking 00-SAIP-77 Technical Alert Implementation & Tracking 00-SAIP-78 Inspection Records & Filing 00-SAIP-79 Assessment Recommendations Tracking System 01-SAIP-01 Small Pipes & Nipples Inspection Programs 01-SAIP-04 Injection Points Inspection Programs
3 Objectives
2.1 To measure and monitor the overall performance of the plant inspection units following a predetermined seventeen (17) measures that covers all inspection activities.
2.2 To identify gaps in the seventeen (17) inspection programs and function that include on-stream-inspection program, the relief valve program, welder tracking system and the equipment inspection schedules.
2.3 To verify that Saudi Aramco standards and procedures are being properly implemented along with the applicable industry standards.
2.4 To highlight to plant management gaps in the PIU for timely corrective action.
4 Responsibilities
4.1 The PIU Supervisor shall form a team, two times a year, including representative(s) from other inspection units to measure the performance of his respective unit.
4.2 The PIU Supervisor shall, with transmittal letter from his Div. head/GS, also send all the performance results supported by all documents if requested to the Inspection Department (ID) to update the respective Unit's performance by June 30th and December 31st.
4.3 Upon request of the Facility Manager, the ID should spot-check the performance of the respective Inspection Unit.
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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4.4 The IEU shall make the calculation spread sheet available for the PIUs through ID web site and maintain it as required.
4.5 The IEU shall send the semi-annual PII Report of the PIU to its respective Facility Manager.
5 Scoring Process
5.1 Every six months (End of June and end of December every year), the Plant Inspection Unit Supervisor shall form a team, including a representative(s) from another Plant Inspection Unit (Sr. Inspector or above), to perform the PII scoring of his respective Unit.
5.2 The team shall cover the seventeen (17) measures listed in attachment I.
5.3 The team shall submit the results to the PIU Supervisor with all the documents supporting the Unit's performance calculations.
5.4 The PIU Supervisor should review and confirm the results with the team prior to submittal to ID/OID.
5.5 The final calculations of the Unit performance should be available with all supporting documents for possible verification by IEU.
5.6 IEU/OID can request support documents for verification. Any nonconformance will be returned back to the respective Inspection Unit for correction or clarifications.
5.7 If all results are accepted by IEU, then the Units performance will be reflected in the PII and forwarded to the PIU plant manager.
5.8 In each of the 17 measures, there are questions (Attachment II) that need to be answered to calculate the total scoring for that specific measure. Each question is given a maximum score that can be achieved if the Unit is fully meeting the requirement. Some questions are based on a "yes" or "no" answer while others are percentage-based to help clarify the answer (i.e., the experience level of the unit is to be scored based on the given percentages).
5.9 Questions that are not applicable can be marked with N/A and the program will not consider that specific question in the final calculation (i.e., the rupture disks may not be available at some of the plants in which case the question will not be considered in the total score).
5.10 Each one of the 17 measures has been given a weight factor based on how important they are to the overall performance of the facility.
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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5.11 The minimum acceptable PII score shall be set as 80% for the overall and 60% for the individual programs. These levels will be revised based on performance by the PIU units.
Commentary Note:
These percentages are based on the results obtained after testing this index on selected PIUs.
5.12 The calculation sheet will automatically calculate the overall performance of the Unit based on the calculated scores of the measures. A chart (attachment III) will be generated reflecting the Unit performance for each one of the 17 measures.
5.13 The PII scoring sheet can be obtained from the ID website Operations Inspection Division http://id.aramco.com.sa/site/index.asp?Module=OID.
Revision Summary 31 January 2005 New Saudi Aramco Inspection Procedure.
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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ATTACHMENT I SAMPLE (PII) SUMMARY REPORT
INSPECTION DEPARTMENT
Plant Inspection Index Report
Unit XYZ Inspection Unit Evaluation
Period Jan-Jun, 2005
Systems and Programs Evaluation # INDICES PII COMMENTS 1 Technical Administration 0.6 2 Training & Certification 0.7 3 Relief Valves 1.0 4 Mechanical Inspection 0.8 5 Equipment Inspection Schedule 0.7 6 On-Stream Inspection 0.8 7 Corrosion Control & Monitoring 0.7 8 Welding/Repair Inspection 0.9 9 Coating 0.7 10 Filing/Records Keeping 0.8 11 Civil and Structural Inspection 0.7 12 Electrical Inspection 0.7 13 Nondestructive Testing Operations 1.0 14 Management of Change 0.8 15 Worksheet & Reporting 0.8 16 Management of Recommendations 0.5 17 Positive Material Identification 0.9
PLANT INSPECTION INDEX: 13.1
89% Reduced PII Due to Incident Related to Inspection 84%
Signed by:
Plant Inspection Unit Supervisor Signed
by:
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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Other Inspection Unit Representative
ATTACHMENT II SAMPLE (PII) ENTRY SHEET (Only Shaded Fields are to be filled)
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Has the unit had a study of the workload and experience level to decide the number of inspectors and number of supervisors and whenever new plants are added?
4 4 00-SAIP-73
Based on the above study, does the unit have the proper number of Inspectors, Senior Inspectors and Field Supervisors?
4 3 00-SAIP-73
Is the Supervision assignment continuous? 3 1 What is the average experience level in the Unit? 4 3 Does the Unit have up-to-date written orientation Program for new inspectors? 2 2 CLPM
Is the inspection function independent from other organization to prevent influence? 4 4
Has an incident or unplanned shutdown taken place that was found to be a result of inspection program failure since the last assessment?
6 0
Does the Inspection Unit participate in all Management plant walkthrough inspections and participate in the review meetings?
2 2 CLPM
Does the unit conduct at least monthly safety/communication meetings? 2 2 CLPM
Has the unit conducted the annual self assessment? 4 4 SAEP-308
Tech
nica
l Adm
inis
trat
ion
TOTAL FOR TECHNICAL ADMINISTRATION 35 25
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Does the unit have an individual to coordinate inspector training? 4 4
Is the AJTS training program implemented in the Unit? 4 4 AJTS/Job Description Is there a 1:4 mentorto-mentee ratio in the unit to verify and sign off tasks? 4 4
Is there a written schedule for in-house training? 2 2 Does the Unit have a IDP's for each inspector? 4 4 GI-1809.001 Are Aramco and body certification obtained per Job description for all inspectors? 4 3
AJTS/Job Description
Does the unit have a system for regularly informing its inspectors of the revised Standards and procedures? 4 0
Does the Unit have a tracking system for NDT personnel certification validation? 4 4 GI-1809.001
Is the schedule for in-house training followed? 2 2 Do all inspectors have at least one week inspection training course per year? 2 2
Trai
ning
& C
ertif
icat
ions
TOTAL FOR TRAINING AND CERTIFICATION 34 29 Is a Quality manual for PZV in the PZV shop available and followed? If not has the unit highlighted deficiencies to management?
4 4 SAEP-318/319
Are all your RVs tested within EIS (i.e. none overdue without approved deviation request per SAP RV System)?
4 4 SAEP-318/319
Rel
ief V
alve
s
Do you physically check Rupture Discs for integrity? 4 NA SAEP-318/319
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 9 of 21
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Are internal audits conducted on maintenance shops per schedule? 4 4
SAEP-318/319
Is physical check conducted on RV after installation and check list filed including correct installation, car sealing, color-coding, etc)?
4 4 SAEP-318/319
Are mothballed RV properly designated and tracked? 4 4 SAEP-318/319 Is the testing interval reviewed and adjusted based on service, performance and conditions? 4 4
SAEP-318/319
Are valves open to atmospheres regularly checked for open drain 4 4 SAES-J-600
Is the relief valve coordinator trained in SAP system and operations? 4 4
SAEP-318/319
Has the relief valve coordinator completed the AJTS for relief valve inspection? 4 4
Job Description
TOTAL FOR RELIEF VALVES 36 36 Are pressure vessels being inspected by API certified inspectors or by inspectors having more than 20 years inspection experience or have completed AJTS requirements?
4 4 AJTS/Job Description
Are all mechanical inspections being done by API/AWS certified inspectors or under their immediate supervision? 4 3
Is a checklist being utilized when conducting external inspection? 4 4 00-SAIP-75
Mec
hani
cal I
nspe
ctio
n
Are tanks being inspected by API certified inspectors or by inspectors having more than 20 years inspection experience or have completed AJTS requirements?
4 2 AJTS/Job Description
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 10 of 21
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Are piping and pipelines being inspected by API certified inspectors or by inspectors having more than 20 years inspection experience or have completed AJTS requirements?
4 2 AJTS/Job Description
Have all inspectors completed the AJTS for assigned mechanical jobs? 4 4
AJTS/Job Description
Is SAEP-325 being followed all the time when inspecting pressurized equipment? 4 4 SAEP-325
Is risk based inspection or prioritization based on SAEP-325 being used to optimize mechanical inspections? 4 0
SAEP-325, SAEP-343
Are the mechanical inspection tools available to perform the required mechanical inspections (e.g. flash light, pit gauge, hammer, magnet, magnifying glass, etc.)
4 4
Is the external inspection required by SAEP-20 being performed timely (no overdue)? 4 4
SAEP-20 & 00-SAIP-75
Is inspection formally informed of maintenance activities such as during OME meetings? 4 4 00-SAIP-72
TOTAL FOR MECHANICAL INSPECTION 44 35 Are all pieces of equipment included in the EIS as required SAEP-20? 4 4 SAEP-20
Are deviation requests submitted to the Inspection Department (complete & timely)? 4 0 SAEP-20
Is the discretionary letter for over due equipment issued timely? 4 4 SAEP-20
Equi
pmen
t Ins
pect
ion
Sche
dule
Do you have a computerized tracking system for EIS with reminding capabilities and can be accessible by Operations and T&I Planning?
3 3 SAEP-20
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Have you completed initial T&I for all new equipment per SAEP-20? 4 4 SAEP-20
Have you complied with the external inspection requirement as per SAEP-20? 4 4 SAEP-20
Is RBA conducted to optimize inspection? 2 0 SAEP-20 Is EIS evaluation for possible adjustments after T&I conducted and documented? 3 3 SAEP-20
Are road crossing inspection & revalidation conducted per EIS? 4 NA SAEP-20
Is a sub-sea pipeline inspection program functional? 4 NA SAEP-20
Are all Operations Support Facilities listed and inspected per EIS and schedule? 4 4
SAEP-20&SAEP-
309 Are mothballed equipment identified and monitored per SAEP-20 and SAER 2365 ? 3 3
SAEP-20 , SAER 2365
TOTAL FOR EQUIPMENT INSPECTION SCHEDULE 35 29 Do you have an individual coordinating the On-Stream Inspection? 4 4 SAEP-1135
Do you have a system for verifying OSI data errors within 90 days? 4 4
Do you have OSI drawings for all equipment and piping in hydrocarbon service or critical service? 4 4
SAEP-1135 Para 3.1.3.b
Does the inspection Unit have a system to ensure modifying OSI isometric drawings when changes are made to plant?
3 0 SAEP-1135
On-
Stre
am In
spec
tion
Do you have a program for Nipple surveys? 4 4 01-SAIP-01
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 12 of 21
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Do you have chemical injection points and system to monitor them? 4 NA
01-SAIP-10, API-570, Alert -30/97
Are dead legs identified and being monitored? 4 4 SAES-L-310 Para 11.4.5 Are all vessels susceptible for Corrosion Under Insulation and fireproofing identified and included for CUI Inspection?
4 0 SAEP-1135 Para 3.2.5
Is there a system for Inspecting transition area soil/air interface) and splash zones? 4 NA SAEP-1135
Do you perform OSI 6 months prior to T&I? 3 0 Are all your equipment up-to-date with their TMLs (i.e. No backlog)? 4 3 SAEP-1135
Are process piping classified per SAEP-1135? 4 4 SAEP-1135 Do you monitor and document heaters in the creep range for metallurgical aging, creep and/or creep cracking? 4 NA SAEP-325
Do you perform thermography for monitoring hot spots and refractory damage where other methods can not produce the needed information?
3 3 SAEP-20
Do you inspect bolts and guy wires for stacks and flares for structural soundness? 4 4 API 572
Have all your new plants had TMLs baseline readings? 4 4 SAEP-122 Is susceptible flare lines periodically checked for fouling to ensure adequacy for emergency relief? 4 4 API 571
Is the OSI computer program currently functioning to analyze the gathered field data? 4 4 SAEP-1135
TOTAL FOR ON-STREAM INSPECTION 57 46
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Does the unit/division have a corrosion engineer? Or CP specialist for Terminal and Bulk plants? 4 4
Has the corrosion engineer completed the required 3-month training program? 4 4
Is the CE responsibility defined in the OSI procedure? 3 3 SAEP-1135 Is failure analysis conducted on all failures that impact reliability or safety? 4 4 API 571
Is there a leak reporting system documenting leaks and failures impacting reliability or safety? 4 0
GI 2.401/2 & 2.104
Is there a system in place to assure that equipment susceptible to environmental cracking (amine, caustic, wet H2S, deaerators) inspected at appropriate intervals with appropriate NDT method?
4 4 SAEP-325
Do you have a unit-specific corrosion control document (CCDs) or equivalent in place for each of your existing processing units?
4 4
Do you have effective CP for your Tanks, sub-sea structures and buried piping? 4 4
SAES-X-300, 400, 500, 600
Are damage mechanisms other than pitting and general thinning reviewed by a corrosion engineer during set up of the inspection plans?
3 3 SAEP-1135
Is the yearly and quarterly schedule as applicable for monitoring the CP system available, implemented and reported?
4 4 SAEP-333
Cor
rosi
on c
ontr
ol /
Mon
itor
Is the SAEP-333A survey report forms utilized for the CP system survey? 2 2 SAEP-333
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 14 of 21
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Is the low potential reading and/or the CP system deficiencies reported and tracked? 4 4
SAEP-333, GI 428.001
Is the capacity test for the solar system performed every 2 years 4 4 SAEP-333
Is the result of the CP inspection communicated to the inspection Units if done by others? 4 NA SAEP-333
TOTAL FOR CORROSION CONTROL/MONITORING 48 44 Are all welding jobs inspected by certified welding inspectors? 4 4
AJTS/Job Description
Is Welder Tracking System installed and updated? 4 4 SAEP-321
Do you enter welder performance in the WTS? 4 4 SAEP-321
Do you repair ASME vessels by certified shops? 4 NA SAES-D-008
Are welding inspection tools available? 4 4 SAES-W-10/11/12/13 Are shop and field weld inspection covered and roles specified? 4 4
Is shop electrode ovens and electrode handling process periodically checked, results documented and recommendations followed up?
4 4 SAES-W-10/11/12/13 Wel
ding
/Rep
air I
nspe
ctio
n
TOTAL FOR WELDING/REPAIR INSPECTION 24 24
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Are blasters and painters certified by the Unit or are qualifications of contractor personnel (blasters and painters) checked by Unit?
4 4 SAEP-316
Are all coating inspection performed by certified inspectors? 4 4
AJTS/Job Description
Is holiday testing conducted on all critical coating? 4 4 SAES-H-
Are major and premature coating failures investigated and results documented? 4 0
Are coating jobs QA forms filled in and filed? 4 4 SAEP-316 Are sufficient coating inspection tools available to inspect the blasting &coating operations? 4 4 SAEP-316
Coa
ting
Insp
ectio
n
TOTAL FOR COATING INSPECTION 24 20 Is there a clerk in the Unit? 3 3
Is there a procedure to set guidelines for record keeping, retention, indexing etc? 4 4 00-SAIP-78
Are Equipment Files updated/complete? 4 4 00-SAIP-78 Are Aramco report format used always (NDT, HT, etc.)? 4 4 00-SAIP-78 Do you have a system for back-up of Inspection records? 4 4 00-SAIP-78 Do you have an up-to-date master list of all equipment? 4 4 SAEP-20 Do you use computerized inspection data management system to store inspection history? 4 4 00-SAIP-78 F
iling
and
Rec
ords
Are all Deviation requests and discretionary letter available? 4 4 SAEP-20
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 16 of 21
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Are critical records properly protected (e.g. fireproof cabinet) or electronically backed up? 4 4 00-SAIP-78
Do you have all reference material in the Unit if not available through the Intranet? 4 4 00-SAIP-78
TOTAL FOR FILING/RECORDS 39 39 Is the civil inspection performed by a qualified civil inspector? 4 4
Job Description
Do you inspect your pipe rack structure/foundation? 4 4 SAEP-20 Para 5.5.8 Is there a qualified refractory / insulation inspector available? 2 2
AJTS/Job Description
Do you have a Database for all the concrete structures and fireproofing in your plants (both onshore and offshore)?
3 0
Do you grade the concrete deterioration and failure as per the classification described in Aramco standard? 4 4
SAEP-309 Attachment ll
Do you use the checklists for concrete pre-pour inspection, during pouring etc? 4 4
SAEP-20 Para 5.5.8
Do you follow up with the laboratory results of the concrete compressibility tests and keep records in the file? 4 4
SAES-Q-001 Para 16
Are sufficient civil inspection tools available? 4 4 SAES-Q-series Does the unit have a back up inspector for inspection units that has only one inspector? 4 4
Civ
il In
spec
tion
Is the civil inspection required by SAEP-20 being performed timely (no overdue)? 4 4
SAEP-20 & 00-SAIP-75
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 17 of 21
XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Do you make sure that the concrete supplier is approved by the Vendor inspection unit, Dhahran and report to them any standard violations in the concrete plant & transport truck?
4 4 SAEP-112
Is the unit informed of all civil activities (daily/weekly schedule) 4 4
TOTAL FOR CIVIL INSPECTION 45 42 Is the electrical inspection performed by qualified inspectors? 4 4
AJTS/Job Description
Does the unit have a back up inspector for inspection units that has only one inspector? 4 4
Is the electrical inspection required by SAEP-20 being performed timely (no overdue)? 4 4
SAEP-20 & 00-SAIP-75
Does the electrical inspector have tools and technical resources? 4 4 00-SAIP-78
Is the unit informed of all electrical activities (daily/weekly schedule) 4 4 00-SAIP-72
Do you verify that cable splicing is done by certified cable splicers? 4 4 SAES-P-104
Elec
tric
al In
spec
tion
TOTAL FOR ELECTRICAL INSPECTION 20 20
Is there a proper NDT personnel performance tracking program for certification validation? 4 4
SAEP-1140 para 9.4 &
9.5
Is contractor personnel qualification checked? 4 4 AJTS/Job Description
Non
-Des
truc
tive
Test
ing
Does the Unit have enough NDT equipment and material available? 4 4
SAEP-1144/1146 &
ASME V
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Do you have a documented program for calibrating NDT instruments? 4 4
SAEP-1144/1146 &
ASME V
Does the unit have certified level II RTFI? 4 4 AJTS/Job Description Does the unit have a dark room available? 2 2 SAEP-1143 TOTAL FOR NON-DESTRUCTIVE TESTING 22 22 Is the Inspection Unit involved in the Management of change (MOC) for issues affecting equipment integrity? 4 4 00-SAIP-72
Does the Unit get involved in the review of all relevant design packages, repair and modifications? 4 4 00-SAIP-72
Does the Unit get Involved in periodic meeting with operations, maintenance and Engineering (OME) on equipment integrity related issues?
4 4 00-SAIP-72
Is GI 2.60 being followed for acceptance of Units after T&I? 4 4 GI 2.60
Are temporary piping installation/repairs tracked through open worksheet until removal or replacement with permanent fix?
4 4 00-SAIP-72
Do you have limits established for all key and critical process variables that affect corrosion and materials degradation, and are they documented in the operating instructions?
4 0 00-SAIP-72
Does the material specialist or corrosion engineer evaluate the potential corrosion impact of the proposed change?
4 4 00-SAIP-72
Man
agem
ent O
f Cha
nge
(MO
C)
TOTAL FOR MANAGEMENT OF CHANGE 28 24
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Does the unit have a computerized system for Tracking Worksheets? 4 4 00-SAIP-76
Do you reference standards in your WS's? 4 4 00-SAIP-76 Do you highlight WS that are outstanding more than a year? 4 4 00-SAIP-76
Is the Work sheet kept open for temporary repair until it is properly reviewed as permanent or permanent repair is done?
4 4 API 570
Are worksheets highlighted monthly to plant manager for critical or long outstanding worksheet review? 4 4 00-SAIP-76 W
orks
heet
s &
Rep
ortin
g
TOTAL FOR WORKSHEETS REPORTING 20 20 Do you have a procedure for assuring proper handling and compliance with Technical Alerts? 4 0 00--SAIP-77
Do you have a system for tracking self assessment recommendations? 4 0 SAEP-308
Is there a system for tracking and follow up on recommendations issued for proper and timely completion such as PZV shop audit recommendations?
4 4
Are OID Assessments Status reports issued on time to the Inspection Department 4 4 SAEP-308
Do you have any OID Assessment recommendations exceeding the ETC? 4 4 SAEP-308
Man
agem
ent o
f Rec
omm
enda
tions
TOTAL FOR RECOMMENDATIONS IMPLEMENTATION 20 12
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
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XYZ Inspection Unit RANKING FOR PERFORMANCE MEASURES
Jan-Jun, 2005
Prog
ram
Or S
yste
m
Parameter to Measure for the Last 6 Months
Max
Sco
re
Act
ual S
core
Reference Standard
Is PMI inspection done by the Unit on received material? 4 NA SAES-A-206Is PMI of alloy material verified after fabrication? 3 NA SAES-A-206Is SAES-A-206, 00-SAIP-07 followed for marking, reporting and documentation? 4 4
SAES-A-206 00-SAIP-07
Is existing low alloy piping/equipment PMI spot checked during T&Is? 4 NA
Posi
tive
Mat
eria
l Id
entif
icat
ion
(PM
I)
TOTAL FOR POSITIVE MATERIAL IDENTIFICATION 4 4
Document Responsibility: Inspection Department 00-SAIP-71 Issue Date: 31 January 2005 Next Planned Update: 1 February 2008 Plant Inspection Performance Index
Page 21 of 21
ATTACHMENT III
SAMPLE PII Chart for XYZ Inspection Unit
0%20%
40%
60%
80%
100%
Tech
nical
Admi
nistra
tion
Traini
ng &
Certif
icatio
nRe
lief V
alves
Mech
anica
l Insp
ectio
n
Equip
ment
Inspe
ction
Sch
edule
On S
tream
Insp
ectio
n
Corro
sion C
ontro
l & M
onito
ring
Weldi
ng R
epair
Insp
ectio
n
Coati
ng In
spec
tion
Filing
/Rec
ords K
eepin
g
Civil a
nd St
ructur
al Ins
pecti
on
Electr
ical In
spec
tion
Nond
estru
ctive
Testi
ng
Mana
geme
nt of
Chan
ge
Works
heet
& Rep
orting
Mana
geme
nt of
Chan
ge
Posit
ive M
ateria
l Iden
tifica
tion
Insp
ectio
n Sy
stem
s
Performance