OES Inspection Manual

Rev. Number: Document Title: Rev Date:

00 OES-INS-P057 XX-Ago-XX
Document Status: Piping Inspection Procedure Page:
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Piping Inspection Procedure

Review/Revision History
Rev. No. Rev. Date Section/Para. Details Reviewed by

00 XX-Aug-XX All Initial XX

1. Purpose
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Establish the process to ensure all in-service piping systems are inspected in a timely manner, depending on the
following:
 Contents and/or function of the piping system
 Minimum inspection requirements and frequency of inspection
 Classification of piping systems in accordance with API, ABS MODU rules and other regulatory guidance
documentation.

2. Scope
Applies to in-service piping system on OES Group offshore facilities.

3. Responsabilities

3.1 Technical Support

 Provide support to rig personnel to execute the Piping Inspection maintenance as designated in VAMS.
 Ensure shore-based and rig-based Oversight assurance activities are taking place.

3.2 Rig Manager

 Ensure Maintenance for Piping Inspection is performed as designated in the OES Group Asset Management
System (VAMS).
 Ensure rig-based Oversight and Self-Verification assurance activities are taking place.
 Ensure Piping Register is maintained in VAMS.
 Monitor and audit Piping Inspection maintenance on the rig.

3.3 Rig Maintenance Supervisor/Chief Engineer or Barge Supervisor/Engineer

 Supervisingand assistancing the maintenance for Piping Inspection as designated in VAMS.

4. Procedure

4.1 Risk Based Inspection

In order for pipe inspection to remain efficient and effective, resources are prioritized on piping where there is a risk to
health, safety, or the environment. Using a risk based approach assesses severity of failures, frequency of occurrence,
and capability of failure mode detection.

 RBI Method
Probability of failure is an assessment of the likelihood of failure on a system. For piping, the probability of failure is
evaluated from rate of corrosion, pipe wall measured thickness, and the minimum required thickness. Corrosion
rate is established using historical inspection data, however a value of 0.5mm/year is used as the default value for
systems where the historical corrosion rate is unknown. The corrosion rate includes erosion and all other thickness
loss mechanisms. The calculation for the remaining life of the pipe is:

Remaining life = (measured thickness – thickness required) / corrosion rate

Where “thickness required” can be calculated in accordance with ASME B31.3 and does not account for any
corrosion allowance.

Consequence of failure assesses potential risk to personnel, rig safety, and the environment should a failure occur.
Combination of consequence and probability determines risk of failure. The Consequence of pipe failure are
categorized into three classifications, Class A, B, and C depending on contents (hazardous and corrosive contents),
working pressure/temperature and size.

o Class A: Piping with the highest potential that would result in an immediate emergency at failure. Such an
emergency may be safety or environmental in nature due to contents (hazardous, highly corrosive or
flammable), higher pressure (>150 psi for gas, >4000 psi for liquids), run through an electrical switchgear
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room or piping directly connected to a high pressure hose (hose rated above 150psi). The following systems
are considered class A:

 Compressed Air / Nitrogen - If >150 PSI

 BOP Control Fluid - ALL
 High Pressure Mud - ALL
 Choke and Kill / HP Cement - ALL
 BOP/Well Test Lines - ALL
 Hydraulic Oil - If >4000 PSI

o Class B: Services that are flammable but do not significantly vaporize when they leak. Services that are
potentially harmful to human tissue due to contents, medium pressure piping. Services that are considered
safety or environmentally critical or flammable by a rig-specific HSE case. Note that part 7 Surveys of ABS
Rules for Building and Classing of Mobile Offshore Units, January 2020, has no specific requirements for
thickness gauging for Seawater and Bilge & Ballast Systems and other systems. The following systems are
considered class B:

 Other Oil (e.g. Lube oil) - ALL

 Hydraulic Oil - Up to 4000 PSI
 Fire main and deluge - ALL
 Fire-fighting Foam - ALL
 Fire-fighting gas (e.g. CO2) - ALL
 Black Water (Sewage) - ALL
 Waste Oil - ALL
 Diesel Fuel - ALL
 Helicopter Fuel - ALL
 Vent/Sounding H2S – ALL
 Seawater - ALL
 Bilge & Ballast – ALL

o Class C: Services that are essentially non-flammable, nontoxic, not safety nor environmentally critical, and
low pressure piping (rated at 150 psi or below for gas, 550 psi or below for liquids). The following systems are
considered class C:

 Compressed Air / Nitrogen - If ≤150 PSI

 Potable Water - ALL
 Fresh Water - ALL
 Drill Water - ALL
 Brine - ALL
 Steam - ALL
 Grey Water - ALL
 Low Pressure Mud - ALL
 Dry Bulk Cement/Mud - ALL
 Vent/Sounding Fresh Water - ALL
 Vent/Sounding Seawater - ALL
 Vent/Sounding Waste Media - ALL
 Vent/Sounding Fuel/Oil – ALL

The Table in Appendix B of PR-CO-ENG-011 Repair of Piping and Pressure Equipment provides a summary of OES
Group’s classification of piping systems and services.

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4.2 Inspection
Maintenance personnel carry out visual inspections of piping.
All other inspections are to be carried out only by OES Group-approved third-party contractors.

a. Type of Inspection

• Visual
A thorough hand-over-hand approach to identify corrosion, leaks, damage to piping (e.g. dents and
external corrosion), damage to piping stand-offs / hangers, connections, etc. Particular attention should be
paid to welds located near flexible hose connections, brackets and hose retention fittings adjacent to the
pipe to hose connection.

• Liquid Penetrant Examination

Conduct Liquid Penetrant Examination (LPE) on welds where a crack is suspected. Where excessive
vibration was noted during operation, conduct visual inspection of pipe and LPE on welds.

• Thickness gauging - carbon steel piping

Conduct Ultrasonic inspection in the following areas:
o approximately 1ft (0.3m) on either side of welds or connections
o at least every 10ft (3m) on piping runs (sections of pipe between welds or flanged connections)
o Downstream of control valves, orifices and pump discharge
o Any point of flow direction change (e.g. outside radius of elbows)
o Downstream of turbulence inducing sections (e.g. welds or flanges)
o After glycol injection points
o Where rust is visible or severe internal corrosion is present.

Thickness gauging requirements can be found in Appendix B.

4.3 Inspection Frequency

Depending on the class of piping the requirements for the type of NDE inspection, frequency of inspection from
installation date, and quantity of each system to test for in-service piping varies as per TABLE 1 below.

The table outlines requirements on lines that need to be inspected in time. The inspection is preferably done before
every periodic surveys on the pipes that the rig manager is unsure should be replaced those that present the highest
risks, the ones that were not inspected previously or the ones that raised concern during operations.

TABLE 1: Pipe Inspection Frequency

Thickness
Measurement
at Condition Complete
Visual (by rig Visual by 3rd Welds by 3rd
Pipe Class Monitoring Thickness by 3rd
crew) Party Party
Locations Party
(CML’s) by 3rd
Party

5 years (30% of
A Annual 5 Years Annual 5 Years
welds)

B Annual 5 Years 5 Years

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C Annual 5 Years

The 3rd Party Inspection company is responsible to update piping registers/lists inclusive of the remaining life based
on the thickness measurements (both at CML’s and when complete inspections are completed). The Rig Manager is
responsible to provide the original thickness measurements with support from Engineering.
Where less than 100% inspection is required per Table 1, and issues are identified during inspection in Class A
piping, 100% of the system will be subsequently inspected (e.g. if standpipe has less than 5 years remaining life,
inspect HP mud system pipes not inspected recently). For Class B and Class C piping the OIM / Barge Supervisor on
jackups, or OIM / Rig Maintenance Supervisor on floaters (and the attending surveyor if applicable) will determine if
further examination is required to properly evaluate the integrity of the piping system using OES Group’s Risk
Assessment process.
Care must be taken to ensure that thickness measurements are planned and scheduled at intervals that do not
exceed one-half the ‘remaining life’ per the Risk Based Inspection methodology. The following ‘remaining life’
requirements will apply for all piping systems:

Class Remaining Life Action required

Class A and B less than 5 years Send Report to Engineering with an REA within 1 week
of receiving the inspection report to evaluate the
remaining life and recommend a replacement plan.
Class A and B between 5 and 9 Send Report to Engineering. Monitor every 2 to 3
years years coinciding with the rig’s next Intermediate or
Special Periodic Survey. A change out plan will be
developed by the Rig Manager followed by review and
approval of Engineering through a REA.
Class C less than 5 years Pipe shall be monitored and replaced at the next
intermediate or special periodic survey, whichever
occurs first.
Any piping flaw identified during day-to-day maintenance or operations, such as external corrosion, leaks or physical
damage, should be reported as soon as possible as a corrective maintenance service/work order in the rig’s
computerized maintenance system. This will ensure documentation and prioritization of the repairs/replacement.

Note: Class A piping repairs are to be pre-approved by CE through a REA unless deemed an emergency and a threat
to personnel safety, rig safety or the environment. All emergency repairs shall only be conducted following a formal
risk assessment and approved Management of Change and must be followed up with a REA. Most piping repairs will
require a 1h hydrostatic test at 1.5 x working pressure. Class A piping also requires radiographic testing (or phased
array ultrasonic testing) of any weld used for the repair.

Only qualified welders perform piping repairs

4.4 Piping Functional Locations and List

Class A and Class B piping is idententified in VAMS as functional locations for the perspective systems.

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The third party inspection company is responsible for developing a piping inspection register for the piping included in
the thickness inspection onboard. The resultant inspection report including the register must be attached to the VAMS
work order and associated functional location at the end of each inspection.

a) Piping Register
The completed piping register for thickness measurements will be included as attachments in VAMS. For class B
piping, the register is intended to only capture CML’s in lieu of the complete system.

b) Piping register minimum content:

• Piping line description
• Maximum line working pressure
• Line Content: fluid type
• Piping material / grade, outside diameter, original wall thickness, temperature rating
• Minimum required wall thickness (includes corrosion allowance)
• Most recent inspection date
• Calaculated Remaining Life (years) based on API 580

A sample Piping Register is shown in the Appendix. This should be used as a guide and each individual rig
should construct their own Piping Register.

c) New Construction
Submit the initial Piping Register through a REA to Engineering (for review and approval upon completion.
Engineering will then complete the column on the Piping Register labelled “Required Minimum Thickness” for
all piping in the piping Register.

Thereafter, the register will be resent to Engineering within 1 weeks of receipt of the inspection report prior to
the rig’s 5-yearly Special Periodic Surveys for a review of the Corrosion Rates and Remaining Life. Engineering
will then advise of any special requirements for the next inspection’s work plan.

If during an intermediate survey inspection, 25% of the Class A piping systems are found to have between 5 and
9 years estimated life remaining based on established corrosion rates, the inspection reports and Piping
Register shall be sent to Engineering for review and further advisement.

d) Existing Construction
Rig Operations with help from inspection company to review their piping registers for accuracy well in advance
of planned inspections (3 to 6 months). Any changes made to piping system to be refected in piping register and
sent to engineering along with markup of piping diagrams for review.

Thereafter, the register will be resent to Engineering within 1 weeks of receipt of the inspection report prior to
the rig’s 5-yearly Special Periodic Surveys for a review of the Corrosion Rates and Remaining Life. Engineering
will then advise of any special requirements for the next inspection’s work plan.

e) Reporting Requirements:
Ensure that the inspection company provides a detailed report of the results of the inspection for each of the
systems listed above. As a minimum the report must indicate the following:

• Name of the inspection company and inspector.

• Qualifications of the inspector.
• Type of instruments used and date of last calibration.
• Line information taken from the register (location, diameter, fluid type, working pressure, etc.).
• Isometric diagram / drawing of the piping system tested (with UT points, CMLs, welds, flanges, brackets,
locations marked).
• Measured thickness report at each UT point.

This manual is owned by OES. It must not be reproduced in whole or in part or otherwise disclosed without the prior written consent of OES.
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• Photograph of locations where measurements are taken

5. Definitions

Condition Designated locations on piping systems where thickness testing and other NDE tests are
Monitoring conducted. These locations are to be systematically selected and permanently marked on the
Locations (CML) piping itself and also on the relevant P&ID or isometric drawings.
Complete Complete thickness gauging requires Conduct Ultrasonic inspection in the following areas:
Thickness o approximately 1ft (0.3m) on either side of welds or connections
measurement by
o at least every 10ft (3m) on piping runs
3rd Party
o Downstream of control valves, orifices and pump discharge
o Any point of flow direction change (e.g. outside radius of elbows)
o Downstream of turbulence inducing sections (e.g. welds or flanges)
o After glycol injection points
o Where rust is visible or severe internal corrosion is present.

Dye Penetrant A widely applied and low-cost inspection method used to locate surface-breaking defects in all
Inspection (DPI) non-porous materials (metals, plastics, or ceramics).
Eddy Current Eddy-current testing uses electromagnetic induction to detect flaws in conductive materials.
In-service Includes piping placed in operation (installed) and piping systems that are not currently in
operation due to maintenance activity. This does not include piping systems that have been
installed yet have been formally decommissioned.
Magnetic Particle A method of testing for cracks and other defects in a magnetic material, such as steel, by covering
Inspection (MPI) it with a magnetic powder and magnetizing it: any variation in the concentration of the powder
indicates a flaw in the material.
Radiographic X-Ray is used to take an internal picture usually of weld areas in piping to detect cracks, lack of
Testing (RT) fusion, incomplete penetration, internal porosity, slag inclusions, undercutting and concave root
surfaces.
Ultrasonic High frequency sound energy used to conduct examinations and make measurements. Ultrasonic
Testing (UT) inspection can be used for flaw detection/evaluation, dimensional measurements, material
characterization, and more.

6. References

ABS MODU Rules, Part 4: Machinery and Systems

ASME B31.3 – Process Piping (2010)
API 570 – Piping Inspection Code: In-service Inspection, Rating, Repair and Alterations of Piping Systems
API 574 – Inspection Practices for Piping System Components (1998 recommended practice)
API 579 – Fitness-for-Service
API 580 – Risk-Based Inspection (2009 recommended practice)
API 581 – Risk-Based Inspection Technology (2008 recommended practice)
PR-CO-ENG-011 Repair of Piping and Pressure Equipment

7. Appendices
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Appendix A – Piping Registry

RISK BASED INSPECTION PIPING REGISTRY

LOCATION: DATE: RIG:

Wall Thickness Minimum Required Condition (New/ Most Recent

Gas/Liquid/ Piping Material / O.D. (in.) (Note Minimum Wall Installation NDE Method Inspection Remaining Life
Line Name Pressure rating (Psig) Temp Rating (°F) Fittings Material (in.) or Schedule Measured Wall As-Built Drawing # Replaced/ Repaired/ Inspection Comments (Note 3) System
Content Grade 2) Thickness (in.) Date (Note 1) Frequency (Note 5)
(New) Thickness (in.) Existing) Date
(Note 4)

CLASS A PIPING (HIGH RISK PIPING)

a.       HP Mud Lines, Manifolds and Standpipe
0
including gooseneck
Standpipe 1 from MP to rig floor 7500 Mud A519 4130Gr. Q&T 200 UT 0 HIGH PRESSURE MUD SYSTEM – TRANSFER SYSTEM
Standpipe 2 from MP to rig floor 7500 Mud A519 4130Gr. Q&T 200 UT 0 HIGH PRESSURE MUD SYSTEM – TRANSFER SYSTEM
Standpipe Manifold 7500 Mud 200 UT CML 0 HIGH PRESSURE MUD SYSTEM – TRANSFER SYSTEM
From standpipe manifold to TD Gooseneck 7500 Mud A519 4130Gr. Q&T 200 UT 0 HIGH PRESSURE MUD SYSTEM – TRANSFER SYSTEM
Standpipe manifold to choke manifold 7500 Mud A519 4130Gr. Q&T 200 UT 0 HIGH PRESSURE MUD SYSTEM – TRANSFER SYSTEM
MPs relief valves to mud pit 0 HIGH PRESSURE MUD SYSTEM – TRANSFER SYSTEM
MP booster lines to moon pool 5000 Mud A519 4130Gr. Q&T 200 UT 0 LOW PRESSURE SYSTEM – MUD TREATMENT SYSTEM
Booster moon pool to standpipe manifold 5000 Mud A519 4130Gr. Q&T 200 UT 0 LOW PRESSURE SYSTEM – MUD TREATMENT SYSTEM
Booster moon pool to hub clamp moon pool 5000 Mud A519 4130Gr. Q&T 200 UT 0 LOW PRESSURE SYSTEM – MUD TREATMENT SYSTEM
From stand pipe manifold to drillers cabin 7500 Mud A519 4130Gr. Q&T 200 UT 0 STANDPIPE PRESSURE GAUGE [STANDPIPE LOCATION]
From stand pipe manifold to choke and kill
7500 Mud A519 4130Gr. Q&T 200 UT 0 STANDPIPE PRESSURE GAUGE [STANDPIPE LOCATION]
manifold
Each HP mud pumps pressure gauge system 7500 Mud A519 4130Gr. Q&T 200 UT CML 0 STANDPIPE PRESSURE GAUGE [STANDPIPE LOCATION]
b.      Choke and Kill Lines and manifold 0
Kill line 0 BOP STACK
Choke line 0 BOP STACK
BOP control lines 0 BOP STACK
Choke line from drill floor to moon pool 10000 Drill fluid A519 4130Gr. Q&T 200 0 KILL AND CHOKE LINES
Kill line from drill floor to moon pool 10000 Drill fluid A519 4130Gr. Q&T 200 0 KILL AND CHOKE LINES
Hydraulic lines for the BOP in moon pool 10000 Drill fluid 0 KILL AND CHOKE LINES
Accumulators auto shear/ acoustic 0 BOP STACK
Standpipe to choke manifold 0 CHOKE MANIFOLD
Choke line to cellar deck 0 CHOKE MANIFOLD
Choke manifold to mud gas separator 5000 A519 4130Gr. Q&T 200 0 H2S CHOKE MANIFOLD
Choke manifold to flare boom 0 CHOKE MANIFOLD
Choke manifold to flowline 0 CHOKE MANIFOLD
Choke manifold to trip tank 0 CHOKE MANIFOLD
Test line from Cement unit 0 CHOKE MANIFOLD
Drilling HPU to manifold control panel 0 CHOKE MANIFOLD
c.       Cement Lines and manifold 0
Cementing unit piping 15000 Cement A519 4130Gr. Q&T 200 0 CEMENTING UNIT
Cementing unit to drill floor 15000 Cement A519 4130Gr. Q&T 200 0 CEMENTING UNIT
Cement manifold 15000 Cement 200 0 CEMENTING UNIT
Cement manifold to standpipe 15000 Cement A519 4130Gr. Q&T 200 0 CEMENTING UNIT
Test lines from cementing unit to rig floor 15000 Cement A519 4130Gr. Q&T 200 0 CEMENTING UNIT
d.      Well Test Lines including Flare Boom 0
Well test area to manifold GAS 1500 A53 gr.b 200 0 FIXED LINES FOR WELL TESTING
Well test area to manifold OIL 1500 A53 gr.b 200 0 FIXED LINES FOR WELL TESTING
Well test area to manifold DIESEL 1500 A53 gr.b 200 0 FIXED LINES FOR WELL TESTING
Manifold to boom GAS 1500 A53 gr.b 200 0 FIXED LINES FOR WELL TESTING
Manifold to boom OIL 1500 A53 gr.b 200 0 FIXED LINES FOR WELL TESTING
Manifold to boom DIESEL 1500 A53 gr.b 200 0 FIXED LINES FOR WELL TESTING
Air connection boom 0 FIXED LINES FOR WELL TESTING
Choke and kill manifold to well test area 10000 A519 4130Gr. Q&T 200 0 FIXED LINES FOR WELL TESTING
Drill floor to well test area 10000 A519 4130Gr. Q&T 200 0 FIXED LINES FOR WELL TESTING
e.       Moon Pool Test Lines 0
BOP test unit system in moon pool 0 BOP TESTING EQUIPMENT – HANG OFF TOOL
BOP/Choke manifold test unit system 0 BOP TESTING EQUIPMENT – HANG OFF TOOL
BOP HPU room to test pump piping 0 BOP TESTING EQUIPMENT – HANG OFF TOOL
Test stump test piping 0 BOP TESTING EQUIPMENT – HANG OFF TOOL
f.       Riser Boost Lines 0
Conduit A hub clamp to telescopic joint 0 MARINE RISER SYSTEM
Conduit B hub clamp to telescopic joint 0 MARINE RISER SYSTEM

Appendix B – Thickness Gauging Requirements

Take 4 measurements along the girth (90 degrees apart if possible per DETAIL 1 below. Where access is difficult,
take 4 measurements where possible and include issue in the comments on the Piping Register.

A standard clock will be utilized to record thicknesses. Use “typical view” looking
towards flow direction. When pipe is vertical, “A” points towards bow, “B”
towards starboard. For angled pipes, judgment needs to be used to find
configuration closest to requirements.

DETAIL 1
Note: when testing elbows, take 4 measurements where readings are most accurate, preferably along the outside of
the elbow curve.
For each line, choose/find one CML (Condition Monitoring Location) on a straight pipe, preferably where highest
corrosion rate is expected (e.g. downstream of valve or glycol injection point). At that location, record 8
measurements instead of 4, 45 degrees apart (record A2, B2, C2 and D2 in new columns or as comments).

Typical View for CMLs:

D A
2 2

C B
2 2
In areas where UT inspection cannot be completed because of obstructions a close visual inspection shall be
conducted, the areas shall be marked on the drawings and a comment on observed condition shall be included in
the inspection report.

 Thickness gauging – stainless steel piping:

UT inspect pipe Condition Monitoring Locations (CMLs) only.

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Where corrosion/erosion is visible or suspected, grid UT corroded area(s) as required to accurately document
the area and amount of wastage of the corroded area of the piping, include pictures in report when relevant.

Note: Dented stainless steel pipes should be replaced as soon as practicable.

 Weld connections:
UT or other OES Group approved NDE methodology shall be conducted for any weld that raised concerns
during visual inspection. Radiographic testing (RT) or Phased Array UT (PAUT) is preferred for Class A piping.
NDE welds of pipes connected to high pressure flexible hose. Welds located passed the second pipe support
brackets are not as critical, the pipe can change class.

 Hydrostatic/pressure tests:
Test piping to rated working pressure for a minimum of 10 minutes with system fluid and check for leaks.
Ensure that the test pump has been calibrated and is certified and that all pressure relief valves are calibrated,
certified with documentation and correctly installed. Any loss of pressure constitutes an unsuccessful test and
system must be retested once corrective actions are completed.

Note: Extreme caution must be exercised when using pneumatic testing for gas lines as a failure could pose a
significant risk, use water whenever possible then dry with appropriate air flow.

END OF PROCEDURE
This procedure is subject to periodic audits to maintain its effectiveness.

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