01 SAIP 04 - Injection Point Inspection
01 SAIP 04 - Injection Point Inspection
01 SAIP 04 - Injection Point Inspection
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
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.
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.
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
4 Responsibilities
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.
4.4.1 Verifying the line number and location before taking the readings.
4.4.3 Reporting any changes in the isometric drawing to the OSI coordinator.
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
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
5.1.1 Beginning of the circuit upstream of the injection point, (either 12 inches
or 3D whichever is greater).
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).
5.1.7 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.
5.3 The injection point inspection circuit should be identified as such on the piping
inspection OSI isometric drawing (see Attachment I).
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
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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
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
API-571 can be used to assist and identify damage mechanisms associated with
different processes.
7.2 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.
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
7.5 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).
7.6 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.
7.7 Hot to cold mix points should also be evaluated as injection points by the
process/corrosion engineer.
7.8 When the extent of inspection for injection points overlap, the plant corrosion
engineer or OID should be consulted.
7.9 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
30 June, 2004 New Saudi Aramco Inspection Procedure.
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
5
2nd Elbow (or 25
1st Elbow
feet)
2A
8 1D
3D
5D 3 or
9 1 2"
4
10 1
6 D
Mi
dP
oi n
t (I
fA
pp
lica
6A b 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
6A Mid-way between the injection point and 1st elbow if it is more than 25ft.
7 Branch connection
8 1st change of direction
9 2nd change of direction (elbow) or 25' downstream of the 1st change of direction whichever is less.
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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Document Responsibility: Inspection Department 01-SAIP-04
Issue Date: 30 June, 2004
Next Planned Update: 1 July, 2009 Injection Point Inspection Program
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