@atar Petroleum

OPERATIONS DIRECTORATE (VO)

ASSET INTEGRITY

PROCEDURE FOR INSPECTION DEFERMENT

AI-VO-PRC-004 R1
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Offshore Dukhan Mesai Refinery

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 PROCEDURE FOR INSPECTION DEFERMENT
DOC. No AI-VO-PRC-004 Rev. 1

FOREWORD

This document has been developed under the Asset Integrity Team (P2 initiative),
approved by OM(s’) Management and has been endorsed by EXECUTIVE VP,
OPERATIONS, VO for use as Procedure for Inspection Deferment

This document is published for OPERATIONS Personnel, Contractors and Consultants

utilisation. The document in its present form reflects, as far as possible, the current
corporate requirements taking into account the known available industry practices
and the applicable latest national and international codes and standards.

This document is subjected to periodical review to re-affirm its adequacy or to

conform to any changes in the corporate requirements or to include new
developments in its subject matter.

It is recognised that there will be cases where addenda, data sheets, or other
clarifications need to be attached to the document to suit a specific application or
service environment. As such, the content of the document shall not be changed or
re- edited by any user (QP or its contractors, suppliers, agents, etc.), but any
addenda or clarifications entailing major changes shall be brought to the attention of
the custodian department.

, ‹

All comments / views, recommendations about this document shall be forwarded to

the P2 Team leaders and their Facilitator (representative) email @
[email protected]

"Doc. No.: AI-VO-PRC-004 R1 Page 1 of 11

 PROCEDURE FOR INSPECTION
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Rev.

TABLE OF CONTENTS

Page
No.
FOREWORD
1.0 OBJECTIVE ................................................................ 3
2.0 SCOPE ....................................................................... 3
3.0 TERMINOLOGY- DEFINITIONS I ABBREVIATIONS ............ 3
3.1 DEFINITIONS .................................. ... ..................... 3
3.2 ABBREVIATIONS .................................................... 3
4.0 PROCESS / PROCEDURE ............................................... 4
4.1 DR INITIATION ......................................................... 4
4.2 RAT FORMATION........................................................ 5
4.3 PROCESSING AND APPROVING DR ............................. 6
4.4 RECORDS AND IMPLEMENTATION .............................. 7
4.5 DR APPROCAL CERTIFICATE....................................... 7
5.0 REFERENCE STANDARDS AND CODES ........................ 8
6.0 APPENDICES .............................................................. 8
6.1 APPENDIX A: FLOW CHART ........... . ....... ................. .. 9
6.2 APPENDIX B: DEFERMENT REQUEST FORM.................. 10

REVISION HISTORY LOG 11

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 PROCEDURE FOR INSPECTION
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Rev.

1.0 OBJECTIVE

The objective of this procedure is to establish and implement system for deferment
of planned inspection for all Static Equipment, Pressure Relief Devices, Piping and
Pipeline.

2.0 SCOPE

The scope of this procedure covers deferment of planned inspection of static

Equipment including, Topside Piping, Pipeline systems and pressure relief
devices. Process of deferment covers various stages from request initiation,
processing, review and RAT team approval/rejection.
This procedure is applicable to all QP Operations areas (Dukhan, Offshore, Mesaieed
operations, and Refinery).

3.0 TERMINOLOGY- DEFINITIONS / ABBREVIATIONS

3.1 DEFINITIONS
DR Deferment Request, which means a request to postpone
the established inspection date.
Due Date Date in which an Equipment is due for
Initiator inspection. Employee who initiates Deferment
Static Equipment
Request.
Piping Includes pressure vessels, heat exchangers, piping and
storage tanks
Shall
Includes plant piping, topside piping etc.
Should / would
Indicates a Mandatory course of action.
High Critical Indicates a Preferable course of action.
Equipment
Static Equipment having high criticality refer to Risk
based inspection (RBI) assessment or maintenance and
RAT Committee
inspection record.
Risk Assessment Team is a cross functional team
consisting of members from all departments
(Production, Asset integrity, HSE, Maintenance) within
3.2 ABBREVIATIONS the Operational facilities.

AH
Al
DR Asset Holder

HSE Asset Integrity

NSD Deferment Request

OM Health, Safety & Environment
PM Non shutdown
Operation Manager

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P roduction Manager
PROCEDURE FOR INSPECTION
DEFERMENT
Rev.

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 PROCEDURE FOR INSPECTION
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PRD
Pressure relief Devices
RAT
Risk Assessment team
RBI
Risk Based Inspection
SAP
System, Application and Product
TA
Turnaround

4.0 PROCESS / PROCEDURE

Records Procedural Steps Resp.

4.1 DR Initiation
4.1.1 All Static Equipment piping, Pipeline and pressure
relief devices have established inspection intervals,
determined based on Inspection observations,
history, Corrosion rates and RBI analysis.
It is expected that inspection recommendations
(including remedial action) to be implemented in
totality within specified period to ensure integrity of
equipment during operation from Safety and Integrity
point of view.
However, due to certain requirements, it may not be
possible to shutdown of the unit/equipment for AH
carrying out required inspection, at the
Recommended/ established inspection date and
scope.

Situations may arise either to entirely shift Turn

Around (TA) beyond the established frequency or
reduce TA scope by postponing the inspection of
some equipment. TA
Inspection
Plan In such cases, formal Deferment request shall be
initiated.
4.1.2 Inspection Division shall update the RBI with last
date of Inspection and next inspection due date.
Turnaround RBI/ Planning Division shall carry out
“Deadline and freezing date for Monitoring” for all
Inspection activities Equipment by the monthly basis
and generate Work Orders for all Inspection due
within the next call horizon.
Turnaround Division shall take the list of overdue work TA
orders from SAP and circulated to related managers
(on the first week of each quarter).
The list shall include all items, which will become
overdue for inspection (in next 18 months).

AH

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Records Procedural Steps Resp.

4.1.3 The list shall be circulated to Asset Holder,
Business Support, TA Planning and Maintenance
Planning, for
review and input regarding whether equipment, as per
work order can be taken up for inspection as per
established due date.
4.1.4 DR Initiator shall generate the Equipment Inspection
Deferment Request Form, in case of equipment
SAP can't be released for inspection as per established
due date, (at a minimum of three (3) months before
due date), based on the feedback as per 4.1.3.
Deferment process (as per attached flowchart) shall
be completed and documented before equipment is
operated past the established inspection date.
4.1.5 In case DR is not approved before established due
dates and equipment is operated beyond these
established inspection due date, Non-conformance AH
report shall be issued by Asset Integrity.
4.1.6 A dedicated DR form contains fields namely DR
number, short text, Plant, Unit, functional location,
equipment, reason of deferment actual inspection
due date and Proposed Deferment Due Date with
hint of integrity issue , consequence impact and
recommendations. The list of reason of deferment is
as follows:
a) Aligning with TA
b) Awaiting Material delivery
c) Awaiting Technical Resources
d) Facilities Unavailable
e) Business interruption
f) Unable to Isolate
g) Any other issues
DR shall go through the full cycle of review and
DR approval.
Every action in the workflow approval process is
automatically stimulated with a Lotus Notes email,
addressed to the next node and prompting him the
concerned person for the action. The e-mail
provides a hyperlink directly to the specific request
requiring the action. Failing to respond within a
period of three
(3) working days, launches a new email as a
reminder.

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 4.2 RAT / (Risk Assessment Team) Formation
PROCEDURE FOR INSPECTION RAT
DEFERMENT Risk Assessment Team (RAT) shall be formed in
Rev.
each operating location with Departments subject

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 PROCEDURE FOR INSPECTION
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Records Procedural Steps Resp.

matter experts with Terms of reference (ToR). RAT
team is chaired by Process Safety Focal point
Notes:
a) The Risk Assessment Team shall be chaired by
Process Safety Focal Point and shall include all but
not limited to the following representations:
Health, Safety & Environment Division, Concerned
Asset Holder (Operations/Maintenance), Asset
Integrity/ Inspection department, Turn around
division and Reliability Department. The team may
include any other internal expertise also, if deemed
necessary.
b) The final advice by RAT team shall be generated
within 30 calendar days from the date of generation
of the Inspection Deferment Request. All team
members shall be responsible for the fast processing
of the request within their own area of action.
c) RAT team decision will be reviewed by Asset Holder
Manager and Manager (Asset Integrity /
OPERATIONS ENGG (OFF. FLDS) as applicable.)
Inspection
4.3 Processing and Approving Deferment AI
Requests (DR)
4.3.1
After receiving DR from Asset holder, Inspection
division (RBI/IMS) shall carry out thorough technical
DR
assessment of the risks of proposed extensions and
shall identify the interim functional controls (if any); in
accordance with previous history Risk assessment,
consequence impact, integrity concern and
recommendation based on, QP and Industry codes
(Such as API 510, API 570, API 653, API 580, API
579-1, BS7910, API 571, ASMEB31 G, etc.,), Critical
Inspection recommendations, thickness data, PRD
overdue IOW, and history etc.,. Inspection
AI
All submitted Requests received by Inspection
Division, shall be given an unique Serial Number
RAT
4.3.2
With information to AI Manager, OAI (RBI)
assessment results will be provided to RAT
committee for review and evaluation whether the
Risk of deferment is acceptable or not RAT
4.3.3
The Risk Assessment Team evaluation will consider
as a minimum the following

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 PROCEDURE FOR INSPECTION
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Records Procedural Steps Resp.

a) HSE Impact,
b) Inspection/Asset integrity (RBI) assessment,
c) Fitness For Services,
d) Integrated and planned activities,
e) Effects on QP's Operating Philosophy,
f) Plant Operation related Problems, RAT
g) Optimization, and,
h) Any additional financial burden on QP
4.3.4
Depending on the assessment to all, but not limited
to the above, the RAT shall advice either of the
following:
a) Immediate Release of Equipment for Inspection RAT
DR b) Deferred to the date suggested by the
Deferment Request.
c) Deferred to a new date other than requested date.
4.3.5
The RAT assessment results shall be forwarded to
both Asset Holder Manager & Asset Integrity
Manager for approval; and to all RAT Managers for
information

For both approved and rejected DR and any PM/OM

dispute, OM may override decision, based on
additional studies & constraints. Final decision
shall be forwarded to all Managers, DR initiator and
OAI (IMS) for appropriate action(s).
4.4 Records and Implementation Inspection
Al
The Processed Inspection Deferment Request shall
be forwarded to Inspection (OAI) Division with all
DR documentation to maintain DR record.
4.5 DR Approval certificate AH
After approval of DR, a record shall be generated
from SAP with all essential information. Deferment
request shall be closed after it is notified to all
concerned, including DR initiator.

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5.0 REFERENCE STANDARDS AND CODES

5.1 QP RELATED DOCUMENTS

XXXXX RBI Strategies
XXXXX Equipment and piping systems Inspection Strategies

5.2 International Standards & Specifications

API - 570 Piping Inspection Code: In-service Inspection, Rating,
Repair, and Alteration of Piping Systems
API RP-574 Recommended Practice - Inspection Practices for Piping
System Components
API - 510 Pressure vessel inspection Code: In-service Inspection,
Rating, Repair, and Alteration
API - 653 Tank Inspection, Repair, Alteration,
and Reconstruction
API RP 571 Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry
API 579-1/ASME Fitness-For-Service
FFS-1
ASME B31G Manual for Determining the remaining strength of corroded
pipelines
BS 7910 Guide to methods for assessing the acceptability of flaws in
metallic structures

6 APPENDICES
6.1 APPENDIX A Flow chart

6.2 APPENDIX B Deferment request form

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 PROCEDURE FOR INSPECTION DEFERMENT
DOC. No AI-VO-PRC-004 Rev. 1

APPENDIX A: Flow chart

ImmediateAH.AsstINSP/AI Asst
RBI/IMS At MGR RAT TeamRAT MGRAH/AI MGR OM AII MGRS
MGR MGR

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 PROCEDURE FOR INSPECTION
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APPENDIX — B: Deferment request form ^>>Please click here for the fillable form<<<

EQUIPMENT INSPECTION DEFERMENT REQUEST

Request No. j Tag No.
Re qeest Requested by
t
Rant | Unit : System: Functional Location:
Equipment
Descrwt›on Attached List ir ay
Due Dote
For Inspection

DEFERMENT REQUEST BY ASSET HOLDER

JUSTIFICATIOI'J FOR DEFERMENT (adg separate sheet, rf required
\

Deferred lnspecson Date DR lnit›awr Sigr Date Asset holder Ass stant k1anager Sign/Oate

RBI ASSESSMENT REPORT

RBI Team INSPECTIO N Asst MANAGER SiGN'DATE

RAT ASSESSMENT RECOMMENDATION

OE •ERbtENTSupported Ones O No ” yes/ No . p 0e hew
inspection date

Asset Holder Asset Integrity r Maintenance Redat›ilcy HSE Turn RAT Chairman
Operation Operations Eeq k¥ember btember Member around S›gn@ala
awe ioFr.Los s •z - sgn'Date Sign.''Date Member
s'on/Date .Member Sgn7Date

ACCEPT: @ YE S @ No ACCEPT. YES No

ASSET HOLDER {MAMGER y OA (ASSET INTEGR ITY MANA GER}

OPERATIONS MANAGER APPROVAL

RAT Recommended Accepted by both AH & OA OVER RIDE ‹ IF AH S OA confbct t0c RAT Recomm noas
’New lnsoeccon Date Approved RA” Recommendaaon ygg [ {q

OPERATIONS MANAGER (sign & datej

DEFEF'UEMT REQUEST RECORD SERIAL NU •tBER IALLOTTED BY INSPECTION}

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 PROCEDURE FOR INSPECTION
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REVISION HISTORY LOG

Revision Number: 01 Document Revision Date: 11/10/2018

Item Revised: Revision Description Page No.

Remarks :Nil.

Note:

The revision history log shall be updated with each revision of the document. It shall
contain a written audit trail of the reason why the changes/amendments have occurred,
what the changes/amendments were, and the date at which the changes/amendments
were made.

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