VOLUME 3 - INVENTORY

FACILITIES INVENTORY

Procedure Number: INVTY-001-FAC

KUWAIT OIL COMPANY

INDUSTRIAL SERVICES
INSPECTION AND CORROSION TEAMS

BY
CC TECHNOLOGIES
Contract No. 10626
 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
Next Review Date: DD/MM/YY Page ii of iii

REVIEWER LOG:
Name, Title, Team Signature Date Signed
Approver:
Approver:
Reviewer:
Reviewer:
Reviewer:
Reviewer:
Originator:

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
Next Review Date: DD/MM/YY Page iii of iii

REVISION LOG:
Revision Revision Authority Revisor Brief Description of
Number Date Revision
##### DD/MM/YY

DOCUMENT CONTROL LOG:

Controlled Copy #### of ##### Issued to: Name/Title/Team
Review Frequency Annually (Unless otherwise noted)
Computer/Location Reference To Be Determined
Procedure Distribution Responsibility Name/Team
Procedure Update Responsibility Name/Team
Distribution List: Name/Team
Name/Team
Name/Team
Name/Team
Name/Team
Name/Team
Name/Team

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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PAGE NO
1.0 PURPOSE..................................................................................................................... 2
2.0 SCOPE.......................................................................................................................... 2
2.1 BENEFITS
2.2 TERMINOLOGY AND DEFINITIONS
3.0 RESPONSIBILITIES.................................................................................................. 4
3.1 KOC GENERAL
3.2 KOC INSPECTION AND CORROSION TEAM RESPONSIBILITIES
3.3 KOC SENIOR ENGINEER
3.4 KOC INSPECTOR RESPONSIBILITIES
3.5 RESPONSIBILITIES OF THE INSPECTION
ORGANIZATION/AGENCY
4.0 TRAINING AND QUALIFICATION ....................................................................... 4
4.1 TRAINING
4.2 QUALIFICATIONS
5.0 PROCEDURE.............................................................................................................. 5
5.1 DATA GROUPS
5.2 EQUIPMENT/ASSET DATA
5.3 INSPECTION SCOPE
5.4 PLANNING/SCHEDULING
5.5 WORK ORDERS/AUTHORIZATIONS
5.6 INSPECTION WORK ORDER HISTORY
5.7 FITNESS-FOR-PURPOSE EVALUATIONS
5.8 DOCUMENTATION
6.0 DATA REQUIREMENTS .......................................................................................... 9
6.1 EQUIPMENT/ASSET DOCUMENTATION
6.2 EQUIPMENT/ASSET TESTING AND INSPECTION
DOCUMENTATION
7.0 REFERENCED DOCUMENTATION.....................................................................10
7.1 INDUSTRY REFERENCES
7.2 RELATED PROCEDURES
8.0 APPENDICES.............................................................................................................13
APPENDIX A – BASIC DATA STRUCTURES
APPENDIX B – PRIMARY DATA RELATIONSHIPS
APPENDIX C – TYPICAL EQUIPMENT/ASSETS DATA FIELDS
APPENDIX D – EQUIPMENT INVENTORY RECORDS

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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1.0 Purpose
The purpose of this procedure is to provide the Inspection & Corrosion (I&C) Team of the
Kuwait Oil Company (KOC) with guidelines to produce a framework for development of an
asset management (equipment/facility inventory) database. The database is intended, among
other things, to be used by I & C engineers, inspectors and team members for tracking
inspection activities for specific KOC assets contained within the database.

2.0 Scope
This procedure will discuss the guidelines for adopting a basic inventory of what information
and data is required for the KOC I & C team to collect and what are the initial considerations
in setting up this framework that will enable better management (and in time, continuous
improvement initiatives in operation, maintenance and capital investment activities) of the
plant and pipeline inspection activities. This database will be a tool used to improve
inspection and related activities and does not in itself manage the inspection activities.

The database systems discussed in this procedure are based on the use of electronic
spreadsheets such as MS Excel or Access which are amenable for practical use by the I & C
team. Therefore, this procedure will only discuss the very specific needs for inspection
management, with no consideration of the needs of the KOC’s corporate data repositories.
Consequently, this procedure is the starting point for the creation, storage, management and
use of these spreadsheet files. This procedure is not intended to detract from the wider use of
commercial databases (file-based, relational or object oriented); in fact, with careful planning,
it is possible to integrate some of this data with such larger systems. It is beyond the scope of
this procedure to delve into large information management systems or information
management best practices.

2.1 Benefits
Despite the basic functionality of this database, it should be understood that there are some
advantages of this system both with its current capabilities and, with further planning and
development, interfacing or integration with other systems. Advantages of this database
approach are:
a) Reporting capabilities (tabular and graphical reports)
b) Modular features; stores inspection, inventory, operating, etc. fields
c) Interfacing capabilities such that the data can be shared with other KOC programs
(with proper data formatting).
d) Flexible in that customization is not necessary
e) Can be made accessible (i.e., without undue effort) to technical staff needing this
information (multiple use and sharing)

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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The database does not require all the inventory items prior to its use as its development is an
ongoing process. In fact, some of the files will be further developed with ongoing use (e.g.,
inspection history).

2.2 Terminology and Definitions

2.2.1 Asset: A physical component of a facility which has value, enables service to
be provided, and has an economic life greater than one year.
2.2.2 Database: An integrated collection of related data stored as objects.
2.2.3 Equipment/Asset Identifier: This is the primary asset identification number
(identifier) used for the database.
2.2.4 Field: A category of information in a table.
2.2.5 Objects: An identifiable unit in a database, such as a table, report, or form.
2.2.6 Original Equipment Manufacturer (OEM): is a company that uses product
components from one or more other companies to build a product component
that it sells under its own name or brand.
2.2.7 Other Attributes: The range of inspection and other attributes associated with
KOC assets that are relevant to inspection as listed in the database (e.g., asset
condition inspection priority, procurement information).
2.2.8 Primary Key: Uniquely identifies each record (row) in a single table.
2.2.9 Query: A query enables one to “question” the database using different criteria
that can sort, filter, and summarize table data.
2.2.10 Records: collection of all facts and figures relating to an item in a table.
Rows represent the records of a table.
2.2.11 Relational Database: A relational database is based on the relational model
where a set of related tables forms a relational database. Each table consists of
a set of rows and columns. Each row describes one occurrence of an entity.
Each column describes one characteristic of the entity. The relational database
enables the information from forms, queries and reports to be combined to
produce meaningful results.
2.2.12 System Attributes: Information that describes infrastructure assets and the
physical components of KOC equipment/assets.
2.2.13 Table: An object in a database where facts and figures are stored in a two-
dimensional form in rows and columns.
2.2.14 Unique Identifier: Is a data element, or value, in each row that identifies the
row.
2.2.15 Work Order: A specific instance of an inspection (or other) activity that
consumes KOC resources.

3.0 Responsibilities
3.1 KOC General

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

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INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
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The KOC organization will be responsible for:

a) Providing a list of responsible staff personnel to perform the database management
system work.
b) Providing the necessary training requirements for KOC database management
personnel regarding tools, techniques and technical knowledge.

3.2 KOC Inspection and Corrosion Team Responsibilities

The Inspection and Corrosion Team shall be responsible for:
a) Ensuring that all business requirements for database management are provided (e.g.,
data schemes) and constantly met.
b) Providing organization/reporting structure and reports contents requirements for
inspection personnel to obtain for the database

3.3 KOC Senior Engineer

The KOC senior engineer shall be responsible for:
a) Engineering acceptance, approval, and filing of database reports.
b) Ensure the operation, use, maintenance and integrity (security) of the database
information meets the I & C team needs.

3.4 KOC Inspector Responsibilities

KOC inspection personnel shall be responsible for:
a) Ensuring that all database entry and reporting data are obtained in accordance with
applicable KOC requirements
b) Ensuring that the data collection work of the inspection organizations/agencies meet
the same requirements as the KOC organization.
c) Handling and filing of data information.

3.5 Responsibilities of the Inspection Organization/Agency

The KOC-authorized inspection organization or agency personnel will be responsible for:
a) Performing the data gathering work in accordance with the KOC requirements.

4.0 Training and Qualification

4.1 Training
The database administrator/programmer will be trained in a recognized educational or
information management service provider environment.

4.2 Qualifications

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

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INSPECTION AND CORROSION PROCEDURE MANUALS
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Post-secondary degree in computer science or related technical field. Database certificate

from a major database vendor (e.g., Microsoft, Oracle). Three or more years of database
development.

5.0 Procedure
5.1 Data Groups
The basic data groups of this asset management (equipment/facility inventory) database
system are given by its system and other relevant attributes. The following are suggested for
the I & C inspection team:

a) Equipment/Asset Data Information about equipment/assets to be inspected

b) Inspection Scope Creating inspection plans and associating them with
equipment asset records, planning, and scheduling
frequencies
c) Planning/Scheduling Planning work orders, inspection team/personnel,
materials required, inspection procedures/instructions
and other information. Scheduling deals with
priorities, frequencies-time-, cycle-, or condition-
based, and windows.
d) Work Orders/Authorizations Creating, tracking, charging codes and completing
work orders.
e) Inspection Work Order History Storing past work order files
f) Fitness-for-Purpose Evaluation Documenting and filing assessment evaluations
g) Documentation Preparing, reviewing, authorizing, gathering, and
filing inspection reports for each equipment/asset
item.

The data is collected and retained at different levels of detail (attributes) in support of the
KOC inspection program. The aforementioned data types are suggested in the key groups
that are considered important and meaningful for establishing this database. Some
adjustments to wording or terms used may need to be made to suit existing intra-company, of
for that matter inter-company, data reporting and sharing for KOC. The data groups are not
application-based (just raw data repositories) that, if planned correctly, can support other
applications in use by the KOC.
Since all data repositories must be supported by a documented data model (e.g., data
structure), definitions for each data type as well as data formats and data relationships
between data types and naming conventions must be given (e.g., HIC = hydrogen induced
cracking).

A suggested basic data structure is shown in Tables A.1 to A.5 inclusive of Appendix A
below.

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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A suggested primary relationship of these basic groups is given in Figure B.1 of Appendix B.
These relationships enable the database to become a relational database for the data and make
this tool very powerful and effective for KOC.

5.2 Equipment/Asset Data

This information lists the equipment/asset details and related information (attributes). It will
form the nucleus or core information for the database. As information is gleaned from the
inspection activities, it will be recorded against each specific item maintained in this file.
The following steps assist in developing and managing this asset-related data:
i) All inventory of equipment/assets should be recorded and documented in this
repository
ii) Each equipment/asset should be given a unique identifier for this system
iii) Always ensure that the asset location is recorded based on a single standard location
referencing system (geographical, GIS, place name).
iv) Always relate all inspection activities to the unique asset identifier.
An example of an equipment/asset database structure is given in Table C.1, of Appendix C.

5.2.1 Equipment/Asset Hierarchies

It is suggested that the KOC adopt a hierarchy for their equipment/assets based on the
equipment/asset category used to denote the title of each inspection procedure. For
example, the highest hierarchy would be items such as pressure vessels, heaters, heat
exchangers, etc. as used in the procedures titles (see Paragraph 7.0 Related Procedures
for the comprehensive list). From this hierarchy, components of this equipment/asset
category should be listed to a meaningful level (e.g., Pressure Vessels would list
components such as shell plates, internals, relief valves, etc without having to list each
and every item that may be inspected). The level of detail for the major
equipment/asset’s inspection may be obtained by retrieving the previous inspection
record(s). In this way, the database remains manageable as it continues to expand.

5.2.2 Equipment/Asset Identifier

Each equipment/asset requires a unique identifier in order to be maintained in the
database. KOC needs to establish the logic of this identifier as it should link to
existing recording systems in the organization (e.g., accounting, FINDER, etc.), or if
feasible, existing identifiers if they exist. In any event, the identifiers are only limited
by the system’s alphanumeric positions capabilities (often as many as 15 characters).
It is suggested that the identifiers contain an inherent meaning such as GC for
Gathering Center, BS for Booster Station, etc.

5.2.3 Equipment Attributes

Equipment attribute information should include items such as design and operating
conditions, wall thickness readings, wall thickness trends, and process stream

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

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INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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conditions as well as size, coating material, accessibility, location of weld seams and
openings or penetrations, alterations, surface conditions, and other pertinent
information.

5.2.4 Equipment Asset Construction, Repair, Mitigation, Modification, &

Rehabilitation Data
All relevant data relating to the above activities should include the asset identifier, the
date of the activity, the name of the contractor (or in-house team) that did the work,
and the name of the KOC senior engineer and inspector that managed the project for
the KOC.

5.3 Inspection Scope

In order for this activity to proceed, inspectors must know the pertinent details of the system
being inspected. This is categorized into a) System General Information and, b) System
Condition.
a) System General Information: this information will be gleaned from KOC records and
files for the equipment/facility. These files will range from purchasing the item(s) –
vendor or OEM (original equipment manufacturer) files to installing and maintaining
them – KOC in-house operations and maintenance files. Hence, the need to source
construction and maintenance work orders (see below).

b) System Condition: this information is obtained strictly from performing inspection of

KOC equipment and facilities in accordance with relevant procedures (see 7.0,
Related Procedures). Various methods will be employed to obtain this information.
These methods are discussed in the relevant procedures. Each of these procedures
may be given a field in the database program to ensure that the information is
constantly recorded with each inspection.

The procedures range from visual, magnetic particle, dye penetrant, ultrasonic,
radiographic, in-line inspection (ILI) or hydrostatic testing, all nondestructive
processes used by KOC. Further, each inspection procedure must be performed by
trained, experienced, qualified and certified inspectors- as stated in the relevant
procedure, to ensure that the quality of the inspection information meets KOC
requirements.
A field in this group can be established to provide a category for the emphasis or degree of
inspection scope to be performed- i.e., minimum, average or maximum.

5.4 Planning/Scheduling
Planning and scheduling for inspection is described in procedure number PLTIP-001-GEN
and other procedures. These categories of cycle-, time- or condition-based inspection
frequencies, affected also by the geographical location of the facility/equipment within the

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

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INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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KOC, should be noted in this data group. This data group will have a direct relationship with
the work orders/authorizations data field (below).

The time frame for the completion of the program also needs to be established. This will
dictate the amount or resources and support to meet that objective. It will be affected by the
size of the facility or number of components involved.

5.5 Work Orders/Authorizations

One or more work orders may be planned for each project/program, depending upon the size
of that inspection project/program. The work order should have a field for assigning a project
number or identifier. With a proper design of this data group, KOC can use the project
number identifier as the sort field criteria for all work orders associated with a project. This
will enable grouping and displaying planned, actual and planned versus actual resources and
their costs including contract inspection personnel from the inspection organization/agency.

The attributes of the work order group should describe the work to be performed, the asset(s)
the work relates to and the resources devoted/consumed to this work. Some additional
attributes should also be considered and incorporated.
a) Work Order Number or ID: This is the primary work activity identifier (also know as
the primary key) that must be unique and never change for a specific activity.
b) Activity: Is the agreed upon definition of an action to be performed which will
become the fundamental accumulator for resource/cost usage. KOC can expect that
there will be a finite number of activities but they will be performed many times over
in their assets.
c) Equipment/Asset Identifier: The work order number should be associated with the
specific asset’s assigned ID so that all historical information of that asset can be
tracked and used in time to develop asset management strategies.
d) Priority: The urgency or importance of the work order Assignments can be
preventive, reactive or scheduled and unscheduled.
e) Actual Start and End Dates: Actual dates involving in-stream inspections will track
down time.
f) Actual Resource Usage: This information enables quantification (i.e., costs) of
actual resources expended.

The field for authorizations states the department, or if preferred, the KOC manager who
authorizes or authorized the inspection project to be undertaken. This information not only
denotes that proper KOC authorization is given, but also identifies the party responsible for
that authorization for future reference and due diligence recording.

5.6 Inspection Work Order History

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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This part of the database system will maintain a history of all inspection activities for each
equipment asset. This record, or a relation to another field, will show what was inspected,
when, by whom, why the inspection was performed, and what the outcome of that inspection
was. The data can be manipulated to show all the inspections made for like items.

5.7 Fitness-for-Purpose Evaluations

Once inspection is completed and information about the assets is obtained, it will be
meaningful to establish the status or state of health of that component(s) based on an
assessment and evaluation of the inspection results. In addition, it will be meaningful to
record the results of these results (see Volume 10, Procedures for Remaining Life of
Equipment). Those results could lead to the following considerations:
a) Immediate action required to address safety or compliance concerns
b) Future, planned action, scheduled with other activities
c) Formulation of reinspection frequency guidelines based on trending or other means.

5.8 Documentation
Documents will always be an essential component for a comprehensive inventory and
inspection program. The database can be structured to contain or reference all appropriate
document files and locations. Obviously, containing digital records of documentation in the
database will exponentially increase the amount of memory storage space required, but more
importantly it may consume extraordinary resources to enter this data. A staged approach
would be advisable for starting the system by pointing to where the documents and files are
situated, whilst entering it on a piecemeal basis.

6.0 Data Requirements

Template forms for equipment inventory records are provided in Appendix D for:
i) Pressure Vessels
ii) Heat Exchangers
iii) Water Tube Type Boilers
iv) Air Coolers
v) Indirect Type Oil-Fired Heaters
vi) Storage Tanks
vii) Safety Relief Valves

6.1 Equipment/Asset Documentation

The KOC shall maintain permanent and progressive records of the equipment and facilities.
Permanent records will be maintained throughout their service life. Progressive records will
be regularly updated to include new information pertinent to the operation, inspection and
maintenance history. The preferred method of record keeping is to maintain data by
individual equipment or facility. These records shall contain the following information:

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

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INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
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a) Identifications, locations, and lists of associated major components

b) Manufacturer’s/OEM drawings
c) Manufacturer’s specifications and maintenance procedures
d) Records of major repair work
e) Pressure and temperature ratings
g) Reports of previous inspections

Format and content for each type of document shall be specified including where, by whom,
in what format, and for what period archived documents shall be maintained, where each type
of document shall be assigned a unique identification number.

6.2 Equipment/Asset Testing and Inspection Documentation

All inspection and testing activities shall be documented such that a complete service history
shall be available for each item. Such documentation requirements shall ensure a complete
chronological record of all events of the individual component. These events shall include,
but not be limited to:
a) Certification for initial certification and testing,
b) Re-certification following testing/inspection for repair (whether for maintenance, out-
of-spec. operation, or damage events), modification or extended periods of downtime,
and
c) Special non-destructive testing such as magnetic particle, ultrasonic or radiographic,
that may follow repair or be conducted to clarify the nature of a defect identified
during a routine inspection.

7.0 Referenced Documentation

7.1 Industry References
1. Microsoft Access 2000 Bible Quick Start, Roche, D., IDG Books Worldwide, Inc.,
An International Data Group Company, Foster City, CA, USA.
2. Microsoft Excel 2000 Power Programming with VBA, Walkenbach, J., IDG Books
Worldwide, Inc., An International Data Group Company, Foster City, CA, USA.
3. Best Practices for Utility Based Data, A Best Practice by the National Guide to
Sustainable Municipal Infrastructure 2003, Federation of Canadian Municipalities
(FCM) and National Research Council of Canada (NRC), (www.infraguide.gc.ca).
4. Computer-Managed Maintenance Systems in Process Plants, Cato, W.C and Mobley,
R.K., Gulf Publishing Company, Houston, TX, USA.

7.2 Related Procedures

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INSPECTION AND CORROSION PROCEDURE MANUALS
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PROCEDURE NUMBER VOLUME NO.

PLTIP Volume 2- Plant Inspection Procedures
PLTIP-001-GEN General
PLTIP-002-BPV Pressure Vessels (all categories)
PLTIP-003-TNK Storage Tanks (all categories)
PLTIP-004-HXR Heat Exchanger Equipment (all categories)
PLTIP-005-HTR Heaters
PLTIP-006-TUB Direct Fire Water Tube Boilers
PLTIP-007-RLF Safety and Safety Relief Systems
PLTIP-008-FLR Flare Systems
PLTIP-009-WAT Waste Water Treatment Plant
PLTIP-010-OFF Offshore Facilities
PLTIP-011-OEQ Offsite Facilities
PLTIP-O12-RHB Repair, Modification and Rehabilitation of Existing Facilities
PLTIP-013-EQC Procedure for Inspection Report and Equipment Certification
PLTIP-014-DOC Procedure for Electronic Storing, Retrieving & Updating of Reports
INVTY Volume 3 - KOC Facilities Inventory
INVTY-001-FAC

PIPIP Volume 4 – Pipelines and Piping Inspection Procedures

PIPIP-001-GEN General
PIPIP-002-ILI Procedures for Intelligent Pigging of Pipelines
PIPIP-003-HYT Procedures for Hydrostatic Testing
PIPIP-004-DAP Procedures for Direct Assessment of Pipelines
PIPIP-005-PLT Procedures for Inspection of In-Plant Piping
PIPIP-006-TUB Procedures for Tubular Inspection
PIPIP-007-RPR Procedures for Repairs and Modification of Pipelines and Piping
PIPIP-008-RHB Procedures for Rehabilitation of Pipelines
NDTIP Volume 5 – Non-Destructive Testing (NDT) Procedures
NDTIP-001-GEN General
NDTIP-002-RAD Radiographic Testing Procedure
NDTIP-003-UTP Ultrasonic Testing (UT) Procedure
NDTIP-004-MAN Manual Ultrasonic Testing for SCC and HIC

KUWAIT OIL COMPANY (KOC) Contract No. 10626 CC TECHNOLOGIES

 KUWAIT OIL COMPANY (KOC)
INSPECTION AND CORROSION PROCEDURE MANUALS
VOLUME 3 - INVENTORY
FACILITIES INVENTORY
PROCEDURE NUMBER: INVTY-001-FAC
Effective Date: DD/MM/YY Revision No.: 0001 Rev’n Date: 15/07/03
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NDTIP-005-AUT Automatic Ultrasonic Testing for SSC and HIC

NDTIP-006-MPI Magnetic Particle Inspection (MPI) Procedure
NDTIP-007-LPT Liquid PenetrantTesting (LPT) Procedure
NDTIP-008-EDY Eddy Current Examination Procedure
NDTIP-009-MLL Metallographic Examination Procedures of Materials
NDTIP-010-HRD Hardness Testing Procedure
NDTIP-011-PMI Positive Material Identification (PMI)
NDTIP-012-V&D Visual and Dimensional Inspection Procedures
WLDQT Volume 6 – Welding, Welding Procedures, Qualifications and Testing
WLDQT-001-GEN Welding, General Requirements and Inspection
WLDQT-002-PRO Welding Procedure Review and Approval
WLDQT-003-PER Welder Performance Review and Approval
WLDQT-004-MTL Weldability of Common Materials
WLDQT-005-CRA Welding of Corrosion Resistant Alloys (CRAs)
WLDQT-006-PIE Welding of Pipelines and Piping
WLDQT-007-BPV Welding of Pressure Vessels

WLDQT-008-ATL Weld Defect Atlas

WLDQT-009-TMY Welding and NDT Terminology
WLDQT-010-PWT Post Weld Heat Treatment Procedure
PTEST Volume 7 – Pressure Testing
PTEST-001-GEN General
PTEST-002-HXR Testing of Pressure Vessels and Heat Exchanger Unit
PTEST-003-TNK Pressure Testing of Storage Tanks
PTEST-004-PIE Pressure Testing of Pipelines
PTEST-005-RLF Valves and Safety Relief Valve Testing
PTEST-006-PLT Pressure Testing of Plant Piping
LFAPL Volume 8 – Lifting Appliances
LFAPL-001-GEN General
LFAPL-002-MOB Inspection, Testing and Certification of Mobile Cranes
LFAPL-003-OHC Inspection, Testing and Certification of Overhead Cranes
LFAPL-004-OFF Inspection, Testing and Certification of Offshore Fixed Appliances
LFAPL-005-OLA Inspection, Testing and Certification of Other Lifting Appliances

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LFAPL-006-OPR Training and Certification of Lifting Appliances Operators

CORPP Volume 9 – Corrosion and Corrosion Protection Procedures
CORPP-001-CTG Coatings Testing Procedures
CORPP-002-MTL Materials Selection Procedures
CORPP-003-INH Procedures for Corrosion Inhibition and Monitoring
CORPP-004-CPM Procedures for Cathodic Protection Maintenance
RLIFE Volume 10 – Procedures for Determining Remaining Life of Equipment
RLIFE-001-GEN General Approach for Remaining Life and Fitness-for-Service Assessment
RLIFE-002-GCC Procedures for Remaining Life and Fitness-for-Service Assessment for
Critical Components in Gathering Centers

RLIFE-003-BSC Procedures for Remaining Life and Fitness-for-Service Assessment for

Critical Components in Booster Station

Represents the current applicable inspection procedure

Represents a directly related inspection procedure

8.0 Appendices
Appendix A – Basic Data Structures
Appendix B – Primary Data Relationships
Appendix C - Typical Equipment/Assets Data Fields
Appendix D – Equipment Inventory Records

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APPENDIX A
BASIC DATA STRUCTURES

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APPENDIX A

Basic Data Structures

The following tables display a suggested basic level of data attributes that should be collected and stored. These tables will
not be complete but are intended to demonstrate the gist of their contents (as indicated in parentheses).
Table A 1: Basic Asset Attributes
Primary
Key Equipment / Asset Attributes

Coating Materials
Asset ID Type Location Size Install Date Condition Manufacturer
(Internal)
(XXX) (PV) (GC-3) (21/06/03) (New) (Clad) Hooter

Table A 2: Work Order Attributes

Primary
Key Work Order Attributes

Scheduled Performed Estimated Actual

WO ID Activity Type Asset ID Priority
Date Date Resources Resources
(On Stream (20 (1.2x
(XX) (XXX) (Low) (01/06/03) (05/09/03)
Inspection) Man-hours) Man-hours)

Table A 3: Inspection Work Orders History Table

Primary Key Inspection History

Work Order ID Asset ID Inspection Dates Inspection Findings

(XX) (XXX) (DD/MM/YY) (DD/MM/YY)

Table A 4: Inspection Measurement Table

Primary Key Inspection Attributes

Key Measurement Point Asset ID HIC SCC

(Shell No. 1) (XXX) (NIA) (Significant)

Table A 5: Assessment Table

Primary Key Defect Assessment Attributes

Asset ID Key Measurement Point Action Next Scheduled Inspection

(XXX) (Shell No. 1) (Immediate) (2-month)

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APPENDIX B
PRIMARY DATA RELATIONSHIPS

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APPENDIX B
Primary Data Relationships

Work Order # Resources Consumed Work Order Cost

Work Order
History

Activity Scheduled Performed Estimated Actual

WO# Asset # Priority
Type Date Date Resources Resources

Inspection
Activities

Asset # Type Location Size Age Condition Material

System
Attributes

Asset # Repair Type Repair Date

System
Attributes

Fig B.1, Primary Relationships of Base Groups Note: Arrows indicate the linking relationship between tables

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APPENDIX C
TYPICAL EQUIPMENT/ASSETS DATA FIELDS

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APPENDIX C
Table C.1, Typical Equipment/Assets Data Fields

Data Field Description Example

Equipment Data
Equipment Type A code that defines type of equipment BPV for pressure
vessels
Equipment ID Unique equipment identifier
Equipment Description Description of the equipment
Equipment Asset Number A reference number (e.g. accounting)
which may also be a tag number
Location Location of the equipment/asset item GC-1 for Gathering
Center No. 1
Status and Condition Status of item AND its condition based In-service, out-of-
on a numerical rating system service; 0 to 10 with 10
(suggested) being excellent
condition
Date Installed and Record date of status change after
Modified/Rerated/Repaired/Relocated install date, where applicable
Make Make of item
Model Model of item
Serial Number Manufacturer’s serial number
Inspection Status
Next Scheduled Inspection Show scheduled date State Date (Highlight
if within 6 months)
Criticality Code High, Medium, Low
Inspection Frequency Monthly, Annual, 2-yr, 5-yr, 10-yr, etc.
Previous Inspection File Location of previous inspection files I&C File
Number/Location
Follow-Up Alert Highlight if within 6-months
Fan-Out Bulletin Highlight if other similar items prone “Inspect all ACME
to safety, operating or maintenance relief valves on
concerns BPV’s”
Procurement Data
Manufacturer Name of manufacturer
Vendor Name of vendor or OEM
Purchase Date Date of purchase
Purchase Cost Cost to purchase (state year)
Warranty Information Date of warranty expiration

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APPENDIX D
EQUIPMENT INVENTORY RECORDS

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APPENDIX D
Table D.1, Pressure Vessel Equipment Inventory Record

EQUIPMENT INVENTORY RECORD Inventory

PRESSURE VESSELS Record No.: <EQUIPMENT
ASME SECTION VIII ASSET NO>

Area No.: Manufacturer: Section VIII

Onshore Site: Model No.: Division 1:
Offshore Site: Serial No.: Division 2:
Tag No.: Certification No.:
Process: Date Installed:
MAOP: Last Inspection:
Design Pressure:
Design Inspection Results:
Temperature:
Vertical Layout: High Risk Vessel, Class 1:
Horizontal Layout: Low Risk Vessel, Class 2:
Internally Protected
Externally Insulated Status and Condition:
Shell Material:
Shell Diameter
Shell Height
Original Thickness:
Corrosion Allowanc
Field Field Data Relevant File Nos.
No. Equipment Inspection Procurement
Files Files Files
1 PRESSURE VESSEL PROCUREMENT DATA
Manufacturer Data
Vendor Data
Purchase Date and PO No.
Warranty Information
2 PRESSURE VESSEL TECHNICAL DATA
Manufacturers Reports
Manufacturers Original Design Data
Manufacturers Drawings
Maximum Operating Pressure and Temperature Data
Material Standards Data
Manufacturers NDE Examination Records
Manufacturers Inspection Records
3 PRESSURE VESSEL INSPECTION DATA

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Inspection Reports
NDE Assessment Results
Pressure Testing Reports
Inspection Schedules and Frequency
Follow-Ups and Alerts
Corrosion Records
Records of Thickness Measurements
Records of Weld Joint Map
Compliance Certification
4 REPAIRS/MODIFICATIONS/RERATING
Repair and/or Modification Reports
Evaluation Reports
Approved Design Deviations
Welding Procedures and Procedures Qualifications
Records of Pre/Post Weld Heat Treatments
Pressure Test Results
Certification of Compliance
5 PRESSURE VESSEL MAINTENANCE HISTORY
Maintenance Reports
Maintenance Recommendations and Follow-Ups
6 ACCIDENT OR INCIDENT REPORTS

Verified by Name Signature Date

Senior Engineer:
Offshore Engineer:
Onshore Engineer:

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Table D.3, Water Tube Type Boiler Equipment Inventory Records

EQUIPMENT INVENTORY RECORD Record

WATER TUBE TYPE BOILERS No.: <EQUIPMENT
ASSET NO>

Area No.: Manufacturer: ASME Section VI

Onshore Site: Model No.: Division 1:
Offshore Site: Serial No.: Division 2:
Tag No.: Certification No.:
Process: Date Installed:
MAOP: Last Inspection:
Design Pressure:
Design Inspection Results:
Temperature:
Number of Drums: Draft Fans:
Banks of Tubes: Tube Material:
Oil Fired Boilers: Tube Wall Thickness:
Gas Fired Boilers: Tube Corrosion Allowance:
Economizer: Fuel Handling Equipment:
Air Preheater: Flue Stack:
Superheater: Status and Condition:
Field Field Data Relevant File Nos.
No. Equipment Inspection Procureme
Files Files nt
Files
1 WATER TUBE BOILER PROCUREMENT DATA
Manufacturer Data
Vendor Data
Purchase Date and PO No.
Warranty Information
2 WATER TUBE BOILER TECHNICAL DATA
Manufacturers Reports
Manufacturers Original Design Data
Manufacturers Drawings
Maximum Operating Pressure and Temperature Data
Material Standards Data
Manufacturers NDE Examination Records
Manufacturers Inspection Records
3 WATER TUBE BOILER INSPECTION DATA

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Inspection Reports
NDE Assessment Results
Pressure Testing Reports
Inspection Schedules and Frequency
Follow-Ups and Alerts
Corrosion Records
Records of Thickness Measurements
Records of Weld Joint Map
Compliance Certification
4 REPAIRS/MODIFICATIONS/RERATING
Repair and/or Modification Reports
Evaluation Reports
Approved Design Deviations
Welding Procedures and Procedures Qualifications
Records of Pre/Post Weld Heat Treatments
Pressure Test Results
Certification of Compliance
5 WATER TUBE BOILER MAINTENANCE HISTORY
Maintenance Reports
Maintenance Recommendations and Follow-Ups

6 ACCIDENT OR INCIDENT REPORTS

Verified by Name Signature Date

Senior Engineer:
Offshore Engineer:
Onshore Engineer:

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Table D.4, Air Coolers Equipment Inventory Records

EQUIPMENT INVENTORY RECORD Inventory

AIR COOLERS Record No.: <EQUIPMENT
ASSET NO>

Area No.: Manufacturer: Standard

Onshore Site: Model No.: API 661
Offshore Site: Serial No.:
Tag No.: Certification No.:
Process: Date Installed:
MAOP: Last Inspection:
Design Pressure:
Design Inspection Results:
Temperature:
Forced Draft Type: Status and Condition:
Induced Draft Type: Finned-Tube Construction
Number of Bays: Embedded:
Plug Header Type: Integral:
Cover Plate Header: Overlapped Footed:
Bonnet Type Header: Footed:
Fan Driver Type: Bonded:
Field Field Data Relevant File Nos.
No. Equipment Inspection Procurement
Files Files Files
1 AIR COOLER PROCUREMENT DATA
Manufacturer Data
Vendor Data
Purchase Date and PPO No.
Warranty Information
2 AIR COOLER TECHNICAL DATA
Manufacturers Reports
Manufacturers Original Design Data
Manufacturers Drawings
Maximum Operating Pressure and Temperature Data
Material Standards Data
Manufacturers NDE Examination Records
Manufacturers Inspection Records
3 AIR COOLER INSPECTION DATA
Inspection Reports

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NDE Assessment Results

Pressure Testing Reports
Inspection Schedules and Frequency
Follow-Ups and Alerts
Corrosion Records
Records of Thickness Measurements
Records of Weld Joint Map
Compliance certification
4 REPAIRS/MODIFICATIONS/RERATING
Repair and/or Modification Reports
Evaluation Reports
Approved Design Deviations
Welding Procedures and Procedures Qualifications
Records of Pre/Post Weld Heat Treatments
Pressure Test Results
Certification of Compliance
5 AIR COOLER MAINTENANCE HISTORY
Maintenance Reports
Maintenance Recommendations and Follow-Ups
6 ACCIDENT OR INCIDENT REPORTS

Verified by Name Signature Date

Senior Engineer:
Offshore Engineer:
Onshore Engineer:

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Table D.5, Indirect Type Oil-Fired Heaters Equipment (Inventor Records)

EQUIPMENT INVENTORY RECORD Record

INDIRECT TYPE OIL-FIRED HEATERS No.: <EQUIPMENT
ASSET NO>

Area No.: Manufacturer: Standard

Onshore Site: Model No.: API 12K
Offshore Site: Serial No.:
Tag No.: Certification No.:
Process: Date Installed:
MAOP: Last Inspection:
Design Pressure:
Design Inspection Results:
Temperature:
Shell Material: Spiral Type Coil:
Firebox Rating: Split Pass Type Coil:
Firetube Area: Single Pass Type Coil:
Shell Size OD: Fire Tube Wall Thickness:
Coil Pipe Size: Coil Wall Thickness:
Coil Area: Flue Stack:
Removable Coil: Status and Condition:
Field Field Data Relevant File Nos.
No. Equipment Inspection Procurement
Files Files Files
1 HEATER PROCUREMENT DATA
Manufacturer Data
Vendor Data
Purchase Date and PO No.
Warranty Information
2 HEATER TECHNICAL DATA
Manufacturers Reports
Manufacturers Original Design Data
Manufacturers Drawings
Maximum Operating Pressure and Temperature Data
Material Standards Data
Manufacturers NDE Examination Records
Manufacturers Inspection Records
3 HEATER INSPECTION DATA
Inspection Reports
NDE Assessment Results

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Pressure Testing Reports

Inspection Schedules and Frequency
Follow-Ups and Alerts
Corrosion Records
Records of Thickness Measurements
Compliance Certification
4 REPAIRS/MODIFICATIONS/RERATING
Repair and/or Modification Reports
Evaluation Reports
Approved Design Deviations
Welding Procedures and Procedures Qualifications
Records of Pre/Post Weld Heat Treatments
Pressure Test Results
Certification of Compliance
5 HEATER MAINTENANCE HISTORY
Maintenance Reports
Maintenance Recommendations and Follow-Ups
6 ACCIDENT OR INCIDENT REPORTS

Verified by Name Signature Date

Senior Engineer:
Offshore Engineer:
Onshore Engineer:

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Table D.6, Storage Tanks Equipment Inventory Record

EQUIPMENT INVENTORY RECORD Inventory

STORAGE TANKS Record No.: <EQUIPMENT
ASSET NO>

Area No.: Manufacturer: Standard

Onshore Site: Model No.: API 620
Serial No.: API 650
Tag No.: Certification No.:
Storage Fluid: Date Installed:
Design Pressure: Last Inspection:

Design Temperature: Inspection Results:

Tank Capacity: Tank Roof Design:

Tank Height: Tank Bottom Design:
Tank Diameter: Bottom Plate Thickness:
Lining: Bottom Plate Material:
Shell Material:
Original Thickness: Status and Condition:
Corrosion Allowance:
Field Field Data Relevant File Nos.
No. Equipmen Inspection Procurem
t Files Files ent
Files
1 STORAGE TANK PROCUREMENT DATA
Manufacturer Data
Vendor Data
Purchase Date and PO No.
Warranty Information
2 STORAGE TANK TECHNICAL DATA
Manufacturers Reports
Manufacturers Original Design Data
Manufacturers Drawings
Maximum Operating Pressure and Temperature Data
Material Standards Data
Manufacturers NDE Examination Records
Manufacturers Inspection Records
3 STORAGE TANK INSPECTION DATA
Inspection Reports
NDE Assessment Results

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Testing Reports
Inspection Schedules and frequency
Follow-Ups and Alerts
Corrosion Records
Records of Thickness Measurements
Records of Weld Joint Map
Compliance Certification
4 REPAIRS/MODIFICATIONS/RERATING
Repair and/or Modification Reports
Evaluation Reports
Approved Design Deviations
Welding Procedures and Procedures Qualifications
Records of Pre/Post Weld Heat Treatments
Pressure Test Results
Certification of Compliance
5 STORAGE TANK MAINTENANCE HISTORY
Maintenance Reports
Maintenance Recommendations and Follow-Ups
6 ACCIDENT OR INCIDENT REPORTS

Verified by Name Signature Date

Senior Engineer:
Onshore Engineer:

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Table D.7, Safety Relief Valves Equipment Inventory Record

EQUIPMENT INVENTORY RECORD Record

SAFETY RELIEF VALVES No.: <EQUIPMENT
ASSET NO>

Area No.: Manufacturer: Standard:

Onshore Site: Model No.:
Offshore Site: Serial No.:
Tag No.: Certification No.:
Process: Date Installed:
ANSI Class: Last Inspection:

Operating Inspection Results:

Temperature:
Conventional Safety Spring Set Pressure:
Relief Valve:
Balanced Safety Relief: Relieving Pressure:
Internal Spring Relief: Flange Size Inlet and
Outlet:
Pilot Operated Relief: Orifice Size:
Power Actuated Relief: Body and Bonnet
Material:
Temperature Actuated Nozzle and Disk
Relief: Material:
Non-Reclosing Device: Spring Material:
Trim Material:
Field Field Data Relevant File Nos.
No. Equipment Inspection Procureme
Files Files nt
Files
1 VALVE PROCUREMENT DATA
Manufacturer Data
Vendor Data
Purchase Date and PO No.
Warranty Information
2 VALVE TECHNICAL DATA
Manufacturers Reports
Manufacturers Original Design Data
Manufacturers Drawings
Maximum Operating Pressure and Temperature Data
Material Standards Data

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Manufacturers NDE Examination Records

Manufacturers Inspection Records
3 VALVE INSPECTION DATA
Inspection Reports
NDE Assessment Results
Pressure Testing Reports
Inspection Schedules and Frequency
Follow-Ups and Alerts
Corrosion Records
Compliance Certification
4 REPAIRS/MODIFICATIONS/RERATING
Repair and/or Modification Reports
Evaluation Reports
Approved Design Deviations
Pressure Test Results
Certification of Compliance
5 VALVE MAINTENANCE HISTORY
Maintenance Reports
Maintenance Recommendations and Follow-Ups
6 ACCIDENT OR INCIDENT REPORTS

Verified by Name Signature Date

Senior Engineer:
Offshore Engineer:
Onshore Engineer:

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