Inspection Procedure

00-SAIP-73 Inspection Manning Determination Guidelines Document Responsibility: Inspection Department 26 October 2005

Saudi Aramco DeskTop Standards

Table of Contents

1 2 3 4 5 6 7 8

Scope............................................................. 2 Definitions...................................................... 2 Responsibilities.............................................. 3 Instructions..................................................... 3 Methodology................................................... 4 Other Factors Affecting Manpower Determination....................... 6 Datasheet Population..................................... 6 Calculation Module........................................ 8

Attachment I Data Entry/Output Form............... 9

Previous Issue: New

Next Planned Update: 1 November 2010 Page 1 of 9

Primary contact: Nasser M. Balhareth on 874-5018

CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

Scope This Saudi Aramco Inspection Procedure (SAIP) provides guidelines for estimating the optimum manning levels of the plant inspection units (PIUs). This procedure can be used by either the Inspection Department when conducting the plant inspection unit assessment or the plant inspection units when assessing their manpower needs. It provides a consistent measure for level of manning in PIUs.

Definitions Inspection Unit Time (IUT): A unit of time required to conduct a single thorough inspection on the largest plant equipment in a facility. For this module, a power boiler is the largest plant equipment, and the unit of time equals three hours. Total Calendar Man-Hours (TCMH): The calendar year man-hours based on a 40hrs/week work schedule per person. The TCMH used for calculations in this module is 2080 Mhrs/year. Non Work-Available Calendar Man-Hours (NWACMH): The time lost on vacations (176 Mhrs/yr) medical appointments (32 Mhrs/yr), occasional absence (40 Mhrs/yr), training (80 Mhrs/yr), rescheduled days-off (80 Mhrs/yr), Ramadan (40 Mhrs/yr), breaks (260 Mhrs @ 1 hrs/day). The NWACMH used for calculations in this module is 708 Mhrs/year.
Commentary Note: The Non Work-Available Calendar Man-Hours (NWACMH) is based on input from practicing inspection personnel. The model makes some approximations such as that all manpower is Aramcons and Muslims which reduces their work-available man-hours.

Work-Available Calendar Man-Hours (WACMH): The total calendar man-hours (TCMH) minus the Non Work-Available Calendar Man-Hours (NWACMH). This is equal to 1372 man-hours. Effective Man-Hours (EMH): The Man-Hours that can be dedicated for inspection related activities. The effective Man-Hours are a function of the direct inspection experience level and the Work-Available Calendar Man-Hours. Required Man-Hours (RMH): The calculated inspection eman-hours required by a given inspection unit to provide the needed inspection coverage for routine and T&I related activities by each inspection group. Facility Condition Factor (FCF): A correction factor to get the optimum manning level within an inspection unit. The FCF is a function of the average plants age, the unit average direct inspection experience level and the facility's use of a management of change program. Approved Unit Full Jobs: These are approved budget slots for the unit in the department's organization structure. These correspond to specific job codes in a job ladder of a job family. The approved full jobs are used for analytical purposes only in

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CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

comparison to the optimum manpower and the existing manpower. They are not used in the calculations. Grade Code Group (GC): A Grouping of Grade Codes (GC7-8, 9-10, 11-12, 13) within an inspection discipline or work group (PE&W, Elec., Civil, etc.) within an inspection unit. This grouping is used to simplify the breakdown of inspectors within a discipline or a group for ease of calculation of the average experience level and manhours per discipline or group. 3 Responsibilities 3.1 It is the responsibility of the operating organization management to ensure that their plant inspection units (PIUs) are sufficiently manned with qualified manpower to: 3.1.1 Provide adequate inspection coverage to all plant areas and support facilities within their responsibility as defined in SAEP-20 and SAEP-309 respectively. Establish, maintain, administer and optimize other inspection and corrosion control programs such as relief valves administration and OSI, etc. Ensure that inspection programs are properly and efficiently administered. This should include a corrosion control / cathodic protection engineer, and a full or part time dedicated training coordinator (based on PIU size) to ensure that development, training and certification needs of inspection personnel are properly addressed. Conduct self assessments of the various inspection programs to maximize the return from such programs.

3.1.2

3.1.3

3.1.4 3.2

PIU supervisors are responsible for anticipating and providing manpower forecasts in their departments' business plans to offset manpower attrition due to retirement, Chronic Medical Condition (CMC) cases and transfers.

Instructions 4.1 The data required for manpower determination includes but not limited to: 4.1.1 4.1.2 The various inspection programs administered by an inspection unit, The frequency of T&Is in relation to the number of static plant equipment, The facility remoteness from inspection offices, The level of direct inspection experience of each grade code (GC) group within an inspection discipline in a PIU,

4.1.3 The number of issued versus open work sheets, 4.1.4 4.1.5

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CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

4.1.6 4.1.7 4.1.8 4.2

The average facility age and whether the facility has a documented and effective management of change procedure, The frequency and extent of on-stream inspection programs inclusive of special surveys, The contribution of the unit's personnel to non-core inspection activities such as special projects, and support to other organizations.

The module estimates the manpower needs for each discipline (i.e., mechanical, electrical, civil, etc.) and indicates whether there is a deficiency or excess in manpower. Facilities that conduct their T&I's on the bases of total facility shutdown at fixed intervals (5, 7 or 10 years) should not include man-hours needed for the purpose of the T&Is in the overall manpower calculations. For optimum manning, such facilities should not be manned for an activity that takes place once every 5 or 7 years. Instead, these facilities should rely on manpower support during T&I from other plants, contractors or Inspection Department. Facilities which frequently have a number of 5, 7 or 10-year T&I's that occur within any calendar year should include man-hours needed, particularly if a three 8-hour, or two 12hour shift system is used to provide coverage on a 24-hour basis. Upon filling the excel spreadsheet with the required data, the excel program estimates the variance between the Work Available Man-Hours and the Required Man-Hours and converts the variance into manpower figures.

4.3

4.4

Methodology 5.1 The module is designed to estimate the man-hours needed to provide inspection coverage on day-to-day activities and during major shutdowns and T&I's per calendar year and compare it to the Work Available Man-Hours (WAMH) per inspection group. The variance is converted to excess or additional manpower per each inspection group and the optimum unit overall manning level exclusive of the unit supervisor is determined accordingly. The module utilizes an experience-based estimate of the amount of time it takes an inspector to conduct a single thorough inspection on the largest piece of equipment in the facility and the number of inspections conducted on the same equipment for the same purpose. For this exercise, a power boiler is considered the largest piece of equipment in Saudi Aramco facilities that requires an average of three hours for a single comprehensive inspection on all of its components. It is also estimated that during T&Is and routine worksheet related inspections, an inspector will need to conduct at least two thorough inspections and three follow-up inspections. To account for the difference in the size of equipment and the extent of the required inspections, each inspection activity / equipment type is assigned a
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5.2

5.3

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Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

weight factor to determine the percentage of Inspection Unit Time (IUT) spent during a single inspection. (i.e.: 1 for a power boiler, 0.8 for a tall trayed column, 0.7 for a sphere, 0.6 for a pressure vessel, etc.) 5.4 The required man-hours for all inspection activities is determined in a similar fashion with the exception of activities requiring single inspections where the amount is multiplied by a pre-determined quantity (number) of inspection time required for such activities. For example, to determine the Man-Hours required for conducting inspection on relief valves (RVs) by a dedicated RV administrator, the total number of RVs is divided by their T&I interval to obtain the annual number and the result is multiplied by 0.333 (20 minutes / RV) plus the result of the total number of RVs divided by 2 multiplied by 0.167 (10 minutes / RV) if the administrator is also conducting the external inspection of the RVs as well. Otherwise, the result of the external RVs inspection is added to the mechanical inspection required man-hours for the plant equipment / welding inspectors. As a rule of thumb, for determining the man-hours required for a certain type of equipment or activity, the number of equipment or activity is divided by its frequency of inspection (T&I cycle) to get the annual figure, then the number is multiplied by its assigned inspection unit time weight factor, the number of inspections required, and the predetermined inspection unit time of 3 hours. 5.5 The other side of the calculation is based on the effective man-hours (EMH) concept. The direct inspection experience level of inspection personnel and the Work Available Calendar Man-Hours (WACMH) are the two variables governing this calculation. For example, junior inspectors spend more time on handling a certain inspection activity and on training assignments than senior inspectors. Hence, their EMH is considered lower than their WACMH. Field supervisors and senior inspectors, on the other hand, should have mastered their inspection tasks and should have completed most of their training needs which makes their EMH closer to their WACMH. 5.6 To determine the EMH of the various inspection personnel, the WACMH for inspectors in an inspection group is multiplied by the average of direct inspection experience for a grade code group (GC 7-8, 9-10, 11-12, 13) within an inspection group (PE&W, Elec., Civil, etc.). The calculated EMH for the inspection group is then compared to the RMH of the group and the result indicates whether additional man-hours are needed or excess man-hours are available. 6 Other Factors Affecting Manpower Determination 6.1 Manpower determination is affected by the remoteness of facilities covered by a given inspection unit, and the condition of the facilities under inspection in
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Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

terms of their age and whether the facility has an effective management of change procedure. The overall experience level within an inspection unit also affects the calculation. 6.2 For PIU's covering remote facilities to offset the time spent on travel, one (1) hour of travel time per 50 km or a constant eight hours for flying is multiplied with the group's share of the open and closed worksheets and the result added to the Required Man-Hours (RMH) for each group. Round trips as well as the number of inspections spent on open and closed worksheets are considered in the calculation. The overtime spent on non-T&I / major shutdown related activates will be directly added to each group's RMH based on the ratio of the group's RMH, exclusive of over time and travel time, to the Total Unit RMHs. A Facility Condition Factor (FCF) has also been introduced to account for the facility age, operating practices, inspection expertise, and whether the facility is implementing a written and effective Management of Change (MOC) procedure. This factor is multiplied with the variance in manpower for each inspection group to get the optimum manpower level required for that inspection group.

6.3

6.4

Datasheet Population The performance of the calculation module is dependant on the accurate population of its data sheet. To ensure that the sheet is user friendly, directive comments are posted in all data fields. The datasheet is divided into eleven main fields each containing several sub-fields. A brief description of the main fields is provided below: 1. Operating Information: This field includes plant data such as facility age, and whether the facility has an effective management of change. The facility age is an arithmetic average of the age of all plants within the facility. Information in this field coupled with the calculated inspection Unit experience level is essential for determining the Facility Condition Factor (FCF) required for calculating the optimum manning level. Manpower: This field includes a break down of available manpower by discipline, grade code, and average years of direct inspection experience. Individuals such as training coordinators, draftsmen, clerks as well as permanently or temporally assigned engineers who are not directly involved in providing direct inspection coverage or the administration of other inspection or corrosion control programs are not included in this module. Equipment: This field provides an account for all static plant equipment subject to T&I. For ease of calculations, the equipment are broken down to four T&I cycle groups (12~24, 36~48, 60~84, & 120 months). In calculating the required Man-Hours, the average T&I cycle is used (i.e.: 1.5, 3.5, 6 and10 years). Each equipment type is assigned a weight factor related to its size and the inspection time it takes.
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2.

3.

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Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

4.

Inspection Programs: All data related to inspection programs such as external inspection, OSI, electrical, civil as well as corrosion control programs related data are provided under this field. Comments are provided at each program section explaining how the data is used for the different inspection groups and the time it takes to complete each inspection activity. Design Review Packages: All engineering design packages that undergo inspection review are broken down in this field. Comments are provided at this section explaining how the data is used for the different inspection groups and the time it takes to complete packages review. Approved Unit Full Jobs: The approved unit full jobs are listed under this field for analytical purposes upon comparison of the optimum manpower to the existing manpower. Worksheets / Year: The number of issued and closed worksheets in a calendar year is specified in this field. For the purpose of calculation, worksheets are assigned a weight factor of 0.5 of a 3 hours inspection unit times. The discipline inspector will on the average dedicate three inspection unit times per worksheet. Corrosion Control Programs: All corrosion control programs are included under this field. Comments are provided at each section explaining how the data is used and the time it takes to complete them. Project Support: This field is dedicated for the manpower support to projects provided by the plant inspection unit. Comments are provided at this section for utilization of the man-hours spent on project support with respect to each inspection group. Average Total Overtime / Year: The overtime spent by all inspection personnel including contractors is entered in this field to indicate the over utilization of the unit personnel. The overtime hours is added to the group needed man-hours based on the ratio of the group required man-hours to the overall unit required manhours. Paid and un-paid overtime shall be considered to give a more accurate reflection of man-hours associated with performing inspection activities.

5.

6.

7.

8.

9.

10.

11.

Travel Distance: This field is provided for inspection units that provide inspection coverage to areas not within one fence such as the case for producing and distribution facilities. The travel time is a function of the number of open and closed worksheets multiplied by the number of inspections conducted at a ratio of 1hr/50km. For flights, a constant eight hours is multiplied instead of the ratio. In both cases the round trip is also considered. The resulting value is shared by the different inspection groups based on their share of the issued worksheets.

Calculation Module

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Document Responsibility: Inspection Department Issue Date: 26 October 2005 Next Planned Update: 1 November 2010

00-SAIP-73 Inspection Manning Determination Guidelines

The attached Data Entry form is used for collecting the required data for performing the manning calculations. The latest calculation program can be downloaded from the Inspection Department website.
Revision Summary New Saudi Aramco Inspection Procedure.

26 October 2005

Attachment I. Data Entry/Output Form for Recommended Manning Calculation Module for Plant Inspecti
Inspection Unit Information (1) Operating Example
M.O.C Used

Date Prepared

% over Design Capacity

5
Facility Age (yrs)

No
Current

Required

OSI / NDT Related

5 Manpower
7-8 9-10 11-12

32
13

(2)
Discipline

Recommended Manning Levels PE / W Inspection 0.4 Civil Insp. Electrical Insp. 1.18 R/V Insp. OSI/NDT Insp. 1.7 Corr. Control 8.49 Unit Avg. Expereince Level Total (3) Equipment
Avg.

(4) 0.6 0.4 0.5

years

Ins

Type

OSI TM

27.9

Nippl

PE&W Insp.
PE&W Avg. Experience

2 2 3 6 2 6 1 5 1 5 2 4

2 8 2 10 1 9 5 10 1 10

2 10 13

3 15 1 15 1 15 1 14

9.0 8.8

Type Columns

T&I Frequency (months)

12-24

Inject Dead

36-48

60 - 84

120

CUI lo

9 26 1 17 3 0 46 0 0 1 0 0 1108 0
13

0 5 0 0 0 0 32 0 0 0 0 0 93 0
(7) 14

0 208 4 0 0 17 143 190 0 0 65 0 63 0

Issued

18 277 35 0 0 0 15 35 0 0 0 0 0 0
Closed

Specia

Elec. Avg. Experience

Civil Inspectors
Civil Avg. Experience

Ext. Insp. Elec. Insp. Civil Insp. Corrosion Control Programs (8)

Elec.Inspectors

6.0 Vessels 11.0 Drums 4.0 Tanks 10.0 Boilers 7.0 Htr./Frn./Flr. 9.7 Spheres 2.0 7.5 3.0
Exch./Cond. Fin Fans Rd Crossing

Pipin

Relief

Plant

OSI/NDT Tech.
OSI Avg. Experience

Subs

Supp

RV Inspectors
RV Avg. Experience

Plant

CC.& CP Insp.
CC& CPAvg. Experience

1 9 1 6 46
8

Misce Supp

6.5

CC.& CP Engr.
CC&CP Avg. Experience

(5) Design Pkgs/

yr.

Corro. Mech Elec.

Civil

2 7 3

46
9

46
10

6.5 Loadg Fclty. 1.0 U/G H.C pip. 6.0 Supt. Faclty OSI R. Valves Misc. 2
Grade Codes

Probe

Coupo

Pot. S Trans

(6) Approved Unit Full Jobs (9) Project Support

Worksheets/ yr

5
Civil

7
GC9

11 3

12

Anode

7
Discipline P&E/Welding Corrosion

0
GC9

0
GC10

264
GC11+ (10)

243
Total Over Time/ yr.

Others

Discipline Electrical

GC10 GC11+

Ro

1 1

1 1

Note: All Cells in White Should be filled as appropriate

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