Inspection Procedure

01-SAIP-04 25 July 2009

Injection Point Inspection Program
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Applicable Documents................................... 2
3 Definitions...................................................... 2
4 Responsibilities.............................................. 3
5 TML Assignment............................................ 3
6 Inspection Technique..................................... 4
7 General Guidelines........................................ 5

Attachment I - Example of Thickness

Measurement Locations (TML)
in an Injection Circuit...................................... 7
Attachment II - Neutralizer Injection Nozzle......... 8
Attachment III - Water Injection Nozzle.............. 10
Attachment IV - Corrosion Inhibitor
Injection Nozzle........................................... 12
Attachment V - Sea Water Quench Nozzle........ 13
Attachment VI - BFW Chemical
Injection Nozzle........................................... 14
Attachment VII - Dilute Caustic
Injection Nozzle............................................ 17

Previous Issue: 28 September 2005 Next Planned Update: TBD

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Primary contact: Kakpovbia Anthony Eyankwiere on 966-3-8747226

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

1 Scope

This SAIP provides guidelines to the plant personnel on the injection point's
identification, tracking and monitoring.

2 Applicable Documents

Unless stated otherwise, all Standards, Specifications and Codes referenced in this
procedure shall be the latest issued (including revisions, addenda and supplements) and
are considered a part of this procedure.

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedules
SAEP-1135 On-Stream Inspection Administration

Saudi Aramco Inspection Procedure

00-SAIP-75 External Inspection

2.2 Industry Codes and Standards

American Petroleum Institute

API RP 570 Inspection, Repair, Alteration, and Re-rating of
in-Service Piping Systems
API RP 571 Damage Mechanisms Affecting Fixed Equipment
in the Refining Industry-First Edition

3 Definitions

Injection Point: Locations where relatively small quantities of materials are injected
into process streams to control chemistry or other process variables. Examples of
injection points include caustic, inhibitors, neutralizers, and water injection in overhead
systems, chlorine in reformers, oxygen scavenger, and anti-foam injection.

Injection Point Circuit: The process piping beginning 12 inches or 3D (where D is

nominal pipe diameter), whichever is greater, upstream of the injection point; and ending
at second change in flow direction or 25 feet beyond the first change in direction,
whichever is less, downstream of the injection point including the injection nozzle.

Critical Service: Service in which a leak of the fluid handled could result in hazards
such as fire, explosion, injury to personnel or significant production loss.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

4 Responsibilities

4.1 The Inspection Unit Supervisor shall be responsible for:

4.1.1 Assigning inspectors/technicians to gauge pipe wall thickness at the

injection point Thickness Measurement Location (TML).

4.1.2 Approve repair, modification or replacement recommendations for the

injection points.

4.2 Plant corrosion engineer shall be responsible for:

4.2.1 Identifying all the injection points in the plant.

4.2.2 Reviewing/recommending modifications or replacement of injection

points.

4.3 On-Stream Inspection (OSI) coordinator shall be responsible for:

4.3.1 Tracking and monitoring all injection points on the OSI drawings.

4.3.2 Highlighting the areas that are approaching T-min or area of concerns to
the corrosion engineer, the area inspector, and the field supervisor.

4.4 Plant inspector/technician shall be responsible for:

4.4.1 Verifying the line number and location before taking the readings.

4.4.2 Taking the measurements as per the locations identified in this

procedure.

4.4.3 Reporting any changes in the isometric drawing to the OSI coordinator.

4.4.4 Performing visual inspection as per 00-SAIP-75 guidelines.

4.4.5 Verifying the areas that are approaching T-min and issuing repair,
modification or replacement recommendations for review by the
corrosion engineer and the field supervisor and approval by the unit
supervisor.

5 TML Assignment

5.1 Thickness Measurement Locations (TMLs) in injection point circuits should be at

the following locations on the primary process piping and the injection nozzle:

5.1.1 Beginning of the circuit upstream of the injection point, (either 12 inches
or 3D whichever is greater).

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

5.1.2 Injection point at 360 degree around the injection nozzle itself

5.1.3 Impingement point on the process piping opposite the injection nozzle.

5.1.4 Downstream of the injection point defined as: D, 5D, 10D, midway
between the injection point and the first change in direction (if they are
more than 25 feet apart).

5.1.5 First change in direction such as elbow.

5.1.6 Connections such as fittings within the circuit.

5.1.7 End of the circuit downstream of the injection point which is defined as
second change in flow direction or 25 feet beyond the first change in
direction, whichever is less. If the injection point piping circuit is short
or there is no second elbow, extend the survey to next piece of
equipment as per figure 5-1 of API RP 570.
Commentary Note:

When the limits of the adjacent injection points overlap, they should be
considered as one circuit. The beginning of the circuit is defined in
paragraph 5.1.1 and the end of the circuit is defined in paragraph 5.1.7.

5.2 Relocate D, 5D, or 10D TMLs immediately downstream of a weld joint if it is

approximately within (±) one pipe diameter.
Commentary Note:

Recent failures were identified to be just downstream of welded joints.

5.3 The injection point inspection circuit should be identified as such on the piping
inspection OSI isometric drawing (see Attachment I).

5.4 TMLs should be permanently identified on the piping.

5.5 The above TMLs are the required minimum and additional points may be added
if deemed necessary by the corrosion engineer.

6 Inspection Technique

6.1 Each TML is defined as a band around the pipe rather than a single inspection
point, except for the TML at the injection nozzle impingement point and branch
connection which is a band around the nozzle itself. A full ultrasonic (UT) scan
should be taken around the pipe circumference and the lowest reading recorded.

6.2 If UT measurements are not possible due to high operating temperature or the

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

size of the pipe being too small, then radiography should be used instead of UT
in at least two quadrants of the pipe, preferably 90 degrees apart.
Commentary Note:

To avoid film damage due to high temperature, use an insulating media between
the film and the pipe/nozzle. Also, place a sphere of know size at the source side
to assist in determining the true wall thickness.

6.3 The first change in direction (elbow) downstream of the injection point should
be scanned on a 2-inch grid including 3 inches past the downstream weld joint.
This is because localized corrosion or erosion/corrosion areas may be missed by
spot UT measurement in these segments of the circuit. If scanning of these
areas reveals metal loss, then the affected area should be considered as an
additional TML.

6.4 During each T&I more detailed UT scanning is required by API RP 570 for the
primary process piping located between 12 inches upstream and 10D
downstream of the injection point.

7 General Guidelines

7.1 The inspection frequency should follow SAEP-20, Table-II guidelines.

However the maximum interval should not be more than three years as required
by API RP 570 guidelines.
Commentary Note:

API RP 571 can be used to assist and identify damage mechanisms associated
with different processes.

7.2 New or reinstated injection point in critical service (as define in section 3) shall
be monitored per this SAIP every three months for the first year and then at an
interval per section 7.1 of this SAIP.

7.3 Identify and list all the injection point circuits in the plant(s) and indicate on the
OSI drawings. The injection points should reference and be marked on the
P&ID.

7.4 Implement a systematic monitoring program for injection point circuits as

outlined in this procedure.

7.5 If an injection point is located immediately upstream of a change of direction it

should be relocated. Such action is advisable since accelerated corrosion is most
likely to happen at components downstream of the change in direction in the
injection circuit.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

7.6 Remove and inspect all injection quills during each T&I. Inspect for
erosion/corrosion and fatigue type cracking. Check the quill type (design),
metallurgy, length (center line with respect to the main line) and dimensions to
ensure that the injected fluid will not impinge on the inner wall of the process
pipe. If no inspection history exists for a quill, then the quill should
immediately be radiographed to verify its condition (see Attachments II-VII).

7.7 During initial T&Is, ensure that detailed UT scanning of each injection point
circuit is completed. If a COSASCO fitting is used as an injection point it
should be radiographed for corrosion/mechanical damage to the quill threads.

7.8 Hot to cold mix points should also be evaluated as injection points by the
process/corrosion engineer.

7.9 When the extent of inspection for injection points overlap, the plant corrosion
engineer or OID should be consulted.

7.10 The inspection unit filing system should include a common package for each
injection point including P&ID, SIS to establish T-min, simplified ISO drawing
showing TMLs, OSI Form 8281 data entry sheet, material list, concentration and
type of chemical injected.

Revision Summary
25 July 2009 Revised the "Next Planned Update." Reaffirmed the contents of the document, and reissued
with no other changes.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment I – Example of Thickness Measurement Locations (TML)

in an Injection Circuit

5
2nd Elbow (or 25

1st Elbow
feet)

2A
8 1D
3D
5D 3 or
9 12
"
4

10 1
6 D

Mi
dP
oin
t (If
Ap
plic
ab
6A le
*)

TML # Description
1 3D Upstream limit or 12" whichever is greater.
2 Impingement point
2A Injection nozzle
3 1D Downstream
4 5D Downstream
5 Fittings
6 10D Downstream
st
6A Mid-way between the injection point and 1 elbow if it is more than 25ft.
7 Branch connection
st
8 1 change of direction
nd st
2 change of direction (elbow) or 25' downstream of the 1 change of direction
9
whichever is less.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment II – Neutralizer Injection Nozzle

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment II – Neutralizer Injection Nozzle (Cont'd)

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment III – Water Injection Nozzle

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment III – Water Injection Nozzle (Cont'd)

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment IV – Corrosion Inhibitor Injection Nozzle

CORROSION INHIBITOR INJECTION NOZZLE

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment V – Sea Water Quench Nozzle

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment VI – BFW Chemical Injection Nozzle

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment VI – BWF Chemical Injection Nozzle (Cont'd)

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment VI – BFW Chemical Injection Nozzle (Cont'd)

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-04
Issue Date: 25 July 2009
Next Planned Update: TBD Injection Point Inspection Program

Attachment VII – Dilute Caustic Injection Nozzle

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