0002_600

Saudi Aramco 7180 (5/89)

SAUDI ARABIAN OIL COMPANY (Saudi Aramco)GENERAL INSTRUCTION MANUALISSUING ORG.

SUBJECT:

G.I. NUMBER

ISSUE DATE REPLACES

APPROVAL PAGE NUMBER

OF

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

INSPECTION DEPARTMENT

PLANT/UNIT ACCEPTANCE AFTER T & I SHUTDOWN

2.600

06/19/2002 1/1/1992

MGR 1 4

4

Approved

CONTENT:This Instruction outlines the procedure for accepting plants and/or units for return toservice after T&I shutdown and establishes conditions which must be met before plant acceptance ispossible. The text includes:

1 Acceptance of Major Units2 Acceptance of Other Units3 Responsibilities4 Acceptance Committee5 Acceptance Procedures6 Tightness Testing Procedures

1.0 ACCEPTANCE OF MAJOR UNITS:

Before a major plant or unit is returned to service after T&I shutdown, it shall be inspected andaccepted by the Acceptance Committee.

1.1 During the pre-T&I Superintendents Meeting, a decision shall be made by both OperationsSuperintendent and Maintenance Superintendent as to type of acceptance required, i.e. what isthe composition of Acceptance Committee for the particular plant or unit.

1.2 A T&I Acceptance Report, Saudi Aramco Form 3060, shall be prepared for each unitacceptance and distributed by the Maintenance representative to all Committee Members.

2.0 ACCEPTANCE OF OTHER UNITS:

Other plants or units not considered in Paragraph 1 above shall also be inspected and accepted by theconcerned operating Foreman, Inspector (Plant Equipment) and the Maintenance T&I Director orMaintenance Engineer, as appropriate, before being returned to service after T&I.

2.1 In certain cases the concerned operating Superintendent may request inspection and acceptanceby the full Acceptance Committee and will advise the operating Foreman accordingly.

3.0 RESPONSIBILITIES:

3.1 The concerned operating Superintendent shall normally act as Chairman of the AcceptanceCommittee but may select an operating Foreman to act in this capacity.



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3.1.1 The Chairman shall be selected prior to completion of the T&I and the Maintenance T&IDirector shall be advised accordingly.

3.2 The Maintenance T&I Director shall

3.2.1 Alert the concerned operating Superintendent and the Committee Chairman at leastTWO DAYS in advance of the time the T&I is expected to be completed and the plant/unit ready for Committee inspection.

3.2.2 Notify the Committee Chairman at least ONE DAY before the plant/unit will be readyfor final T&I inspection.

3.3 The Committee Chairman shall alert all members of the Committee at the earliest possible timeand shall inform each member of the acceptance meeting time and place at least EIGHT hours inadvance.

3.4 Committee members must assemble at the designated time and place and be prepared to statetheir exceptions to T&l completion PRIOR TO AND AT the plant/unit inspection.

3.4.1 Each committee member shall follow the T&I closely and as far in advance of the fullacceptance meeting as possible submit to the Maintenance T&I Director a preliminaryexception list.

3.4.2 The full committee membership must be present at the final acceptance meeting. Theplant/unit being inspected may not be returned to operation until the committee hasfinished the inspection and signed the T&I Acceptance Report, Saudi Aramco Form3060. PRIOR TO T&I FINAL ACCEPTANCE MEETING ALL EXCEPTION ITEMSREQUIRED FOR START UP MUST HAVE BEEN COMPLETED.

3.5 The inspection supervisor shall ensure:

3.5.1 Inspection's pre -T&I items have been completed.

3.5.2 All repairs have been accomplished in accordance with the applicable codes/standards.

3.5.3 All non-destructive testing has been completed prior to final plant/unit acceptance.

4.0 ACCEPTANCE COMMITTEE:

The Acceptance Committee shall normally composed of the following:

4.1 The operating representative who will act as Chairman.

4.2 The concerned operating Foreman.

4.3 The Supervisor, Inspection, or a qualified representative designated by the Supervisor,Inspection.



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4.4 Maintenance T&I Director and/or Maintenance Engineer.

4.5 Maintenance T&1 Coordinator(s)

4.6 Area Operation Engineer

4.7 Area Safety Engineer or Advisor

5.0 ACCEPTANCE PROCEDURES:

The T&I Acceptance Committee shall:

5.1 Inspect all major plants or units involved to ensure that the following conditions are met:

5.1.1 All T&I work has been completed or is in the final stages of completion.

5.1.2 All T&I debris has been removed from the on-plot area.

5.1.3 All T&I materials and equipment have been removed from the on-plot area with theexception of scaffolding.

5.1.4 Painting of lines, vessels and other equipment which cannot be painted in service hasbeen completed.

5.1.5 Plant equipment is safe to operate.

5.1.6 Tightness tests have been passed (see paragraph 6).

5.1.7 All equipment (vessels, columns, etc.) have been internally cleaned and accepted byinspection, maintenance and operations prior to closure and the closure document, SaudiAramco Form 3060, signed by the above parties.

5.2 When each member Or the Committee is satisfied within his area of responsibility that the T&Iis essentially complete as outlined in paragraphs 3.4.1, 3.5, and 5.1.1 through 5.1.6 above, heshall sign the Acceptance Report listing any exceptions.

5.2.1 The Chairman shall note on Form 3060 what work must be done before the plant/unitmay be started up.

5.2.2 Hydrocarbon may not be brought into the plant/unit concerned until the AcceptanceReport has been signed off and the work specified by the Chairman in paragraph 5.2.1above has been completed.

5.3 Should the Committee consider the plant/unit not acceptable for start-up, the Maintenance T&IDirector shall review exception items provided by the Committee and advise the Committeebefore it adjourns when the plant/unit will be ready for acceptance.



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5.3.1 The Committee shall reconvene at this specified time and re-inspect the plant/unit.

6.0 TIGHTNESS TESTING PROCEDURE:

The start-up procedures of most plants include nitrogen, water, air, or steam tightness tests of the majorprocess columns, vessels and piping systems. Pneumatic Tightness Testing will normally requireWRITTEN APPROVAL of the Chief Inspection Engineer and concurrence of Loss Prevention as perAES-A-004. Steam tightness testing could be used where it is not detrimental to an internal coating.These tests should precede completion of the T&l as they usually reveal leaks which must be repairedprior to a plant/unit start-up. This paragraph outlines conditions under which theses tightness test maybe carried out.

6.1 Prior to undertaking a tightness test of a section of a plant/unit, (e.g., the recovery section at theHydroformer), T&l work must be essentially complete in the area affected.

6.1.1 When the area in question has been declared ready, a notation to this effect will beentered in the T&l log book and initialed by the operating Foreman.

6.2 The time of the tightness test shall be agreed upon by the Operations, Maintenance andInspection representatives.

6.2.1 During the tightness test, T&l work in the affected area will be held to an absoluteminimum or suspended if possible and all non-essential personnel will be kept out of thearea by the use of rope, chain, or other suitable barriers.

6.3 When the tightness test has been successfully completed, a notation to this effect will be enteredin the T&l log book and initialed by Operations, Maintenance and Inspection representatives.

Concur:

Manager- Inspection

Vice PresidentSouthern Area Producing

Exec. DirectorNorthern Area Producing

Approved:

Sr. Vice PresidentExploration & Producing

0002_600

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