Inspection Procedure

01-SAIP-06 Inspection of SSSP Underground Storage Caverns Document Responsibility: Inspection Department 31 December, 2003

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 Scope............................................................. References..................................................... Definitions...................................................... Safety............................................................. System Description........................................ Equipment Inspection Schedule.................... Inspection Steps............................................ Documentation............................................... 2 2 4 5 5 6 6 8

Previous Issue: New Next Planned Update: 1 January, 2009 Revised paragraphs are indicated in the right margin Primary contact: M.S. Al-Gahtani on 874-6604

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Document Responsibility: Inspection Department 01-SAIP-06 Issue Date: 31 December, 2003 Next Planned Update: 1 January, 2009 Inspection of SSSP Underground Storage Caverns 1 Scope This procedure applies to SSSP Caverns designed in accordance with API STD 620, Low Pressure Storage Tanks. Design pressure in the vapor space is no more than 15 psig. The cavern tank steel lining is defined as a leak proof and gas tight steel construction for the containment of liquid petroleum products. 2 References The following references were used in the preparation of this procedure. 2.1 Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-20 SAEP-316 SAEP-1142 SAEP-1145 Equipment Inspection Schedule Performance Qualification Coating Personnel Qualification of non-Saudi Aramco NDT Personnel Liquid Penetrant Examination

Saudi Aramco Engineering Standards SAES-D-100 SAES-D-108 SAES-H-001 SAES-H-100 SAES-H-102 SAES-W-017 Design Criteria of Atmospheric and Low Pressure Storage Tanks Storage Tank Integrity Selection Requirements for Industrial Coatings Painting Requirements for Industrial Facilities Safety Requirements for Painting Welding Requirements for Tanks

Saudi Aramco General Instructions GI-0002.100 GI-0002.102 GI-0006.102 Work Permit System Pressure Testing Safely Isolation, Lockout, and Use of Hold Tags

Saudi Aramco Form and Data Sheet 2694-ENG Data and Operating Limits Sheet - Pressure Vessels

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Document Responsibility: Inspection Department 01-SAIP-06 Issue Date: 31 December, 2003 Next Planned Update: 1 January, 2009 Inspection of SSSP Underground Storage Caverns 2.2 Industry Codes and Standards API PUBL 207 API RP 575 API STD 620 API STD 653 API STD 2000 Preparing Tank Bottoms for Hot Work Inspection of Atmospheric and Low Pressure Storage Tanks Design and Construction of Large, Welded, LowPressure Storage Tanks Tank Inspection, Repair, Alteration, and Reconstruction Venting Atmospheric and Low-Pressure Storage Tanks

Definitions Auxiliary Piping and Equipment: Auxiliary piping and equipment includes: vapor header; inert gas supply header product header; drain system and collection drum; and pressure relief valves. Inspector: A Saudi Aramco Employee qualified to the criteria specified in the Company's Plant & Equipment (P&E) Inspector Job Descriptions recognized by the Organization and Industrial Engineering Department (O&IE), and a member of a business line Operations Engineering/Inspection Unit, or a qualified contract P&E Inspector. Cavern Tank: SSSP storage tanks located underground. Coating Inspector: An Inspector certified Level II in coatings inspection according to SAEP-316. Crawler: A remote controlled Ultrasonic thickness device with a permanent magnet that can be tethered or not tethered. Expansion Bellows: A sealing mechanism that prevents vapor from escaping around piping that passes through the roof of the cavern. Kicker Plate: The curved plate section that connects the cavern wall to the floor. Magnetic Flux Leakage (MFL): MFL is a nondestructive testing method that is used to inspect storage tank floors. The basic principles involved in this tool include the saturation of the floor plate with a magnetic flux and the detection of flux leakage.

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Document Responsibility: Inspection Department 01-SAIP-06 Issue Date: 31 December, 2003 Next Planned Update: 1 January, 2009 Inspection of SSSP Underground Storage Caverns On-Stream Inspection: The external inspection of piping or pressure vessels while in service. The Inspection usually consists of visual and the collection of thickness data by several Non Destructive Testing methods. Pressure Drop Test: The stripping pit is filled with a liquid and the head pressure is observed for a set period of time to determine if a leak exists. Safety Instruction Sheet (SIS): SIS contains safe operating limits, protective devices, and special safety precautions. Suction Pit: A pit located at the lower end of the cavern where the submersible pumps take suction. Stripping Pit: The stripping pit is located below the suction pit and consists of a drum and submersible pump to remove water that is present in the product. 4 Safety 4.1 4.2 4.3 4.4 All inspection and testing shall be in full compliance with GI-0002.100, "Work Permit System." All inspection and testing shall be in full compliance with GI-0006.102, "Isolation, Lockout, and Use of Hold Tags." All pressure testing shall be in full compliance with GI-0002.102, "Pressure Testing Safely." All blasting and painting operations shall be in compliance with SAES-H-102, "Safety Requirements for Painting."

System Description 5.1 Structural Steel Floor 5.1.1 The Cavern floor is comprised of an in-situ cast concrete slab inlaid with steel backing strips, to form a grid pattern, upon which, steel plates are laid to form a smooth solid steel floor. The steel floor plates are joined together and to the steel backing strips utilizing full penetration buttwelds. The transition piece between the cavern floor and walls is a fully welded curved kicker plate.

5.1.2 5.2

Structural Steel Walls

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Document Responsibility: Inspection Department 01-SAIP-06 Issue Date: 31 December, 2003 Next Planned Update: 1 January, 2009 Inspection of SSSP Underground Storage Caverns 5.2.1 The cavern walls are constructed of a matrix of hot rolled steel beams complete with stiffing and anchor bolt/plates. Pre-formed steel plates are then full penetration but-welded to the matrix of steel beams to form a smooth solid steel wall. The void space behind the steel wall plates is then fully backfilled concrete to form a composite steel/concrete structure.

5.2.2 5.3

Structural Steel/Cavern Tank Roof 5.3.1 5.3.2 5.3.3 The roof is comprised of a matrix of hot rolled steel beams formed in an arch shape. This matrix includes stiffening and anchor plates/bolts. The interior of the arch shape is then clad with pre-formed plates joined together with full penetration butt welds. The exterior of the arch is backfilled with concrete to form a composite steel/concrete structure. The interior arch plates are attached to the cavern wall plates by full penetration butt welds.

Equipment Inspection Schedule Test and Inspection Intervals 6.1 6.2 6.3 The initial T&I interval, as recommended by the Manufacturer, and allowed by SAEP-20, shall be two (2) to five (5) years. The subsequent T&I interval shall be ten (10) years, or 120 months, based on anticipated coating life, per SAEP-20 paragraph 5.5.9. On stream inspection (OSI) interval for auxiliary piping and equipment shall be no more than one-forth the remaining life or five (5) years, whichever is less, and in accordance with SAEP-20, Table II..

Inspection Steps 7.1 Coating Inspection 7.1.1 Inspect visually the internal epoxy coating of the shell, floor, and roof for any defects such as cracks, bubbles, or blisters. Coating repairs are to be done per SAES-H-100, paragraph 8.3 and inspected by a Saudi Aramco certified Level II Coatings Inspector. The results of the coating inspection shall be used to determine further inspection requirements for the steel lining. This is based on the assumption that the integrity of the

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Document Responsibility: Inspection Department 01-SAIP-06 Issue Date: 31 December, 2003 Next Planned Update: 1 January, 2009 Inspection of SSSP Underground Storage Caverns steel lining is unchanged as long as the coating on the product side does not show any signs of deterioration or failure. 7.1.2 Apply dye penetrant examination (PT) to the area of coating failure, after the coating has been removed, to determine if there are any reject able linear defects are present.

7.2

Inspection for Corrosion and Metal Failure 7.2.1 Using a flashlight held close to and parallel to the plate surface, visually inspect the welds and plate surface of the floor, walls, and roof for corrosion, signs of leakage, and defects such as buckling and cracks. Use the appropriate NDT method to further investigate failures and develop the required repair procedure. 7.2.2 Visually inspect the vertical sleeves, sleeves entrances through the roof, and structural supports for suction and fill piping. Continue the inspection inside the pump pit to include the walls, welded cross-joints, and stripping pit internals. Special attention is to be paid to coating of the sleeves supporting structure, as possible vibration could cause damage to welds and create cracks that will be visible in the coating. At the vertical sleeves with "bellows" the two (2) bolts mounted underneath the flanges are to be removed to inspect the internal bellows space (refer to Drawing 1-S-AD-DS-CT-200-99785 and Work Procedure 5-A-A5-ST-E-0005). Also, a pressure test and vacuum box test should be applied.

7.2.3

7.2.4

7.2.5 High stress areas such as: roof plate joint welds; welds at junction of wall plate and floor; monorail attachments to cavern walls; suction pit; and stripping should be inspected thoroughly for cracking. 7.2.6 An adequate number of ultrasonic thickness measurements, number and location to be decided by the Inspector, should be taken on the roof and wall sections to establish a corrosion rate and determine if metal loss has taken place. An automated permanent magnet crawler could be used for this purpose.

7.3

Evaluation of Bottom and Suction Pit 7.3.1 After visual inspection is complete, perform thickness measurement of the total floor using Magnetic Flux Leakage (MFL) floor scanner with an

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Document Responsibility: Inspection Department 01-SAIP-06 Issue Date: 31 December, 2003 Next Planned Update: 1 January, 2009 Inspection of SSSP Underground Storage Caverns electromagnetic coil. This will give an overall view of the floor condition and identify areas of corrosion. 7.3.2 Areas identified with MFL having thickness less than nominal thickness according to the SIS sheet, shall be evaluated using Ultrasonic Testing (UT) method. 7.3.3 7.4 Potential corrosion areas not accessible by the floor scanner shall be measured by UT method. These areas will be selected by the Inspector.

Stripping Pit Non destructive methods such PT, MT, and Ultrasonic angle beam inspection should be performed on the welds attaching the stripping pit to the suction pit, especially if there are cracks in the coating. Also, a pressure drop test should be done.

Documentation A permanent and continuous set of records shall be maintained by the proponent Inspection Unit on each cavern tank. The records shall include but are not limited to the following: a. b. c. d. e. Current Safety Instruction Sheet, Saudi Aramco Form 2694-ENG. Manufacturer's Data Report. Past T&I reports (including corrosion rates, test results, repairs, and coating information). Corrosion and remaining life of each component of the cavern. Equipment Inspection Schedule (EIS).
Revision Summary New Saudi Aramco Inspection Procedure.

31 December, 2003

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