Best Practice SABP-A-053 23 August 2015 Qualification of Service Providers for Corrosion Management Program (CMP) Deployment for Existing Facilities Document Responsibility: Responsibility: Corrosion Control Control Standards Committee Committee
Saudi Aramco DeskTop Standards Table of Contents
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Scope.................. Scope............................... ......................... ......................... ......................... ................... ....... 2
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Conflicts and Deviations............................................... 2
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References......... References........................ ............................ ............................. ............................ .............. .. 2
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Definitions........... Definitions......................... ........................... ............................. .............................. ................ 2
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Qualification Criteria for CMP Service Providers.......... 3
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CMP Service Provider Selection.............. Selection.. ...................... .................... .......... 4
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Service Provider Performance Review................. Review........ ................. ........ 4
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Approved Approved List of Service Providers................ Providers.............................. .............. 5
Appendix I - CMP Scope Scope of Work for Service Service Providers..... Providers..... 6 Appendix II - Minimum Qualifications Qualifications of Key Key Personnel..... Personnel..... 9
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Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
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Scope This Best Practice provides qualification criteria for service providers for the deployment of Saudi Aramco’s Aramco’s Corrosion Corrosion Management Program (CMP) for existing facilities. Deployment of CMP shall follow the requirements laid out in Saudi Aramco Engineering Procedure “Corrosion “Corrosion Management Program Deployment for Existing Facilities” Facilities” SAEP-43 and the “Corrosion Management Program Manual” SABP-A-033 SABP-A-033.. This document also addresses the selection process and performance review of CMP service providers.
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Conflicts and Deviations Any conflicts between this Best Practice and other app licable Saudi Aramco Engineering Standards (SAESs), Materials System Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the company or buyer representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran.
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References The following is a summary of the Saudi Aramco d ocuments relevant to this best practice:
Saudi Aramco Engineering Procedures SAEP-43
Corrosion Management Program Deployment for Existing Facilities
SAEP-1135
On-Stream Inspection Administration
Saudi Aramco Engineering Standard SAES-L-133
Saudi Aramco Best Practice SABP-A-033
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Corrosion Protection Requirements for Pipelines, Piping and Process Equipment
Corrosion Management Program (CMP) Manual
Definitions Approval : Written authorization authorization by the Manager, Manager, Consulting Services Department, Saudi Aramco, Dhahran. Acceptable Service Provider : A service provider where approval is not required when Page 2 of 10
Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
placing a purchase order for his service. After the order has been placed, the supplier of this product must ensure that he complies with all aspects of the purchasing contract (e.g., must meet Saudi Aramco requirements). Corrosion Management Program (CMP) : Corporate Program developed by CSD aimed at proactively reducing corrosion failures and improving plant availability and integrity without compromise to safety and the environment. environment. Key elements of CMP include risk assessment, corrosion loop development, plant integrity windows, CMP Key Performance Indicators, CMP dashboard, technology deployment or development, corrosion talent development and the plant-specific corrosion control document. License Agreement : A contract between a supplier and an owner of rights to an equipment design, allowing a supplier to either (1) assemble the equipment using all the pieces provided by the design owner or (2) assemble the equipment using a combination of pieces provided by the design owner and pieces manufactured by the licensee to the design owner's detailed drawings/specifications. The contract between the licensor and licensee would (1) require the licensee to follow the licensor manufacturing procedu res and be routinely audited by b y the licensor for compliance and (2) require the equipment to be marketed and labeled using the licensor's brand name.
is responsible to to provide the Service Provider : The person/company, etc., who is services to Saudi Aramco.
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Qualification Criteria for CMP Service Providers CMP service provider qualification process is based on three criteria and a scoring system, as follows: a)
Technical Proposal This has been addressed by evaluating the clarity and quality of the technical proposal submitted by the service provider and gauging his level of understanding of the CMP deployment requirements.
b)
Technical Qualification This has been addressed by evaluating the technical capabilities of the service provider and his past experience in carrying out services similar to CMP. This takes into account the availability of the required engineering specialties, an assessment of any submitted resumes of key personnel and a review of any past experience and clients’ list.
c)
Deployment Plan This has been addressed by evaluating evaluatin g the service provider deployment strategy including the mobilization of personnel, availability of all required resources Page 3 of 10
Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
locally and the potential need to subcontract any part of the service to a third party. Each of the above criteria is evaluated using a questionnaire and scored according to the system displayed in Table 1. A score of 70 (out of 100) is set as the basis for qualification. Table 1 - Evaluation Criteria Scoring System #
Criteria
1
Proposal clarity, quality and level of understanding understandin g of requirements requirement s
30
2
Availability Availabilit y and quality of required specialties (including quality of CVs)
40
3
Relevance of past experience
20
4
Availability of resources locally
10
Total Score Score
6
Max Score (Points)
100
CMP Service Provider Selection A facility requiring CMP deployment shall acquire bids from the list of approved service providers from Section 8. 8. These bids shall be sent to CSD/AR&IMD/CMG CSD/AR&IMD/CMG for a technical evaluation. This evaluation entails a review of the technical proposal and the resumes of the staff/engineers deployed by the service service provider. The facility shall then consider commercial bids from the technically-approved service providers proposed by CSD/AR&IMD/CMG.
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Service Provider Performance Review The performance of the service provider shall be evaluated at the end of each deployment by the proponent organization and CMG per the scoring criteria is given in Table 2. 2. The purpose of this evaluation is to ensure continuous improvement of CMP. CMP. Table 2 - Service Provider Performance Scoring Criteria #
Criteria
Max Score (Points)
1
Corrosion Control Document (CCD) quality and compliance to SAEP-43
50
2
Deployment according to agreed plan (time and scope)
30
3
Proponent facility satisfaction with the CCD and the deployment process
20
Total Score
100
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Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
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Approved List of Service Providers 8.1
Refer to the following link to obtain the current approved list of service providers for CMP studies. Link: https://sharek.aramco.com.sa/ Commentary Note: Procuring a CMP study from a non-approved service provider shall be at the discretion the Manager of Consulting Services Department, Dhahran. Requests for approval of an alternate service provider shall be supported by documentation identifying how the alternate service provider would better-serve Saudi Aramco over the already-approved service providers.
8.2
Maintenance of the list of approved CMP service providers is under the responsibility of CSD/AR&IMD/CMG.
8.3
A CMP service provider must maintain an accepta ble level of quality of service to remain in the approved list. A score of 80 (out of 100) in the criteria criteria outlined in Table 2 is set as the basis for remaining in the approved a pproved list.
23 August 2015
Revision Summary New Saudi Aramco Best Practice.
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Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
Appendix I - CMP Scope of Work for Service Providers The responsibilities of the service provider shall include, but not limited to the following scope of work: 1. Perform work process gap analysis:
This activity shall compare the corrosion management work processes existing at the facility with those described in related Saudi Aramco Engineering Procedure for CMP deployment and the CMP Manual. The service provider shall facilitate and lead a workshop involving all the participants to discuss all “Operate & Maintain” work processes processes and document gaps gaps that may exist exist at the facility. facility. The deliverable deliverable from from this this activity shall list all gaps identified and an action plan to address these gaps. These gaps may consist of corrosion or inspection/monitoring procedural rectifications, reporting mechanisms, availability of tools and technologies, performance measurement/tracking and human resource development. 2. Conduct an inspection/corrosion historical review and identify major corrosion challenges/solutions:
This activity shall include, but not limited to, the review of plant information, focusing on major or chronic corrosion challenges, inspection/repair/replacement failure history, incident investigations, process upsets, process variables and operational practices. In addition, it shall include a plant assessment, focusing on major corrosion challenges, locations exhibiting corrosion Classes 0 and 1 (SAEP-1135 SAEP-1135)), chronic fouling areas and equipment or piping nearing their end of life. A list of plant information information as documented in the CMP Manual shall be used as a checklist for this review. The deliverable from this task shall include appropriate recommendations addressing proactively all corrosion, materials degradation and fouling issues encountered in this e xercise. 3. Develop corrosion loops:
The service provider shall facilitate and lead an interactive workshop to involve the proponent’s process, operation, corrosion and inspection engineers. The workshop shall (i) review process, operating / design / start-up / shutdown / upset conditions, contaminants, (ii) identify the materials of construction, (iii) identify active and potential damage mechanisms, (iv) identify existing corrosion barriers barriers and their performance / effectiveness and (v) develop corrosion loops. The main deliverable from this workshop shall include, (i) process description of the loop, (ii) materials of construction, (iii) the damage mechanisms identified and the process/material parameters driving these mechanisms, (iv) the existing corrosion corrosion barriers in place and their performance, i.e., justification or supporting statements for the presence of these mechanisms.
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Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
4. Customize the damage mechanism narratives:
The service provider shall customize the Saudi Aramco generic damage mechanism narratives to the specific conditions of the plant for each active or potential damage mechanism. The narrative shall consist of the damage description, the affected affected materials, the control methodology, the inspection or monitoring techniqu es, frequency and KPIs. 5. Perform corrosion risk assessment:
The service provider shall perform a corrosion risk assessment using the results of a quantitative Risk Based Inspection (RBI) study undertaken previously b y the service provider himself or others. The objective of this assessment is to gain an understanding of the risk levels resulting from the RBI study and contrast these with the major corrosion challenges identified in Task 2 above. 6. Develop Plant Integrity Windows (PIWs):
The service provider shall develop the PIWs focusing on mechanical and chemical variables affecting corrosion/material degradation, e.g., metal temperature, velocity, differential pressure, pH, contaminant or corrodent concentration (chlorides, H2S, CO2, caustic, oxygen, ammonium chloride, ammonium bisulfide, ammonium chloride, hydrogen partial pressure, etc.). etc.). Each PIW shall have a tag, tag, lower and upper limits, frequency of measurement and urgency, the consequences of deviation, the possible root causes of the deviation and the actions required to remedy the deviation and restore normality. 7. Develop Key Performance Indicators (KPIs):
The service provider shall develop leading and lagging KPIs relevant to the corrosion performance of the plant; these measures shall be both proactive and reactive, focusing on internal, financial and result KPIs. 8. Develop CMP Dashboard:
The service provider shall develop the CMP Dashboards for the following levels of personnel: •
Vice President Dashboard (Highest Level)
•
Manager Dashboard (High Level)
•
Superintendent Dashboard (Medium Level)
•
Supervisor and Engineer Dashboard (Detailed Level)
The CMP Dashboard is a visual display of the KPIs and PIWs showing targets, compliance, impact of deviations and actions to rectify these deviations and restore Page 7 of 10
Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
integrity. This dashboard is intended for the future development as a live/online IT IT solution for compliance tracking and remediation of d eviations. 9. Identify corrosion management recommendations, solutions, and technologies:
The service provider shall derive appropriate corrosion management strategies to supplement the existing practices practices in the plant. The service provider shall also identify identify any new or existing technologies that will make an impact on the proactive p roactive corrosion management process at the facility. facility. These should include, but not limited limited to, corrosion monitoring, corrosion protection (organic coating, strip lining, weld overlay, thermal spray coating, and cathodic protection), corrosion prediction (software), life assessment, material selection, statistical analysis, etc. 10. Deliver a preliminary closure presentation to plant management:
The service provider shall conclude the CMP deployment activities at proponent site with a closure technical presentation highlighting to plant management the preliminary findings and solutions. It shall include, but not limited to, the following following key points: •
CMP methodology
•
Work Process gap analysis findings
•
Major historical corrosion challenges
•
Key corrosion threats, identified via the corrosion loop workshop
•
Risk assessment findings
•
Preliminary PIWs and KPIs
•
Corrosion management strategies & technologies
•
Path forward (remaining activities/assessments, action plan to replicate CMP on other units at facility (including plant prioritization criteria).
11. Develop Corrosion Control Document (CCD):
The service provider shall develop a unit-specific CCD and submit it for plant proponent and central engineering reviews. The CCD shall include an executive summary, the comprehensive assessment findings of all the above scope of work, conclusions and recommendations. Upon receipt of the review comments on the draft CCD, a final CCD shall be developed and submitted to proponent as the main CMP deliverable. 12. Deliver final closure presentation to plant management
The service provider shall deliver a final closure presentation to plant management summarizing the contents of the corrosion control document with e mphasis on major corrosion challenges, proactive corrosion control measures, required tools and technologies and talent development requirements. Page 8 of 10
Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
Appendix II - Minimum Qualifications of Key Personnel The following are the minimum qualifications of the service p rovider CMP team: 1. CMP Team Leader:
Bachelor of Science or Engineering degree (or higher) in Corrosion, Materials, Metallurgical, Mechanical or Chemical Engineering from an accredited university. 15 years of experience in an asset integrity discipline such as corrosion engineering or corrosion management, risk-based inspection, fitness for service, materials selection, failure analysis, etc. in oil and gas industry.
Chartered Engineer or equivalent preferred
NACE certification or equivalent preferred
API certification preferred Shall be responsible for the overall CMP deployment coordination, execution and service provider single point of contact; responsible for the facilitation of required workshops and contracted deliverables.
2. Materials & Corrosion Specialist (may fulfill the role of CMP Team Leader):
Bachelor of Science or Engineering degree (or higher) in Corrosion, Materials, Metallurgical, Mechanical or Chemical Engineering from an accredited university. 15 years of experience in an asset integrity discipline such as corrosion engineering or corrosion management, risk-based inspection, fitness for service, materials selection, failure analysis, etc. in oil and gas industry. NACE Certified Corrosion Specialist, Senior Corrosion Corrosion Technologist or equivalent. API 571 certification is an advantage. Shall be responsible for addressing all corrosion issues; works with all other engineers on materials / corrosion / welding / coating / chemical & water treatment / cathodic protection / inspection / operations issues, development of corrosion loops, undertaking of plant assessment and development of recommendations, PIWs, KPIs and dashboard, customization of damage mechanism narratives and development of CCD.
3. Chemical & Water Treatment Specialist (if required*):
Bachelor of Science or Engineering degree (or higher) in Chemistry, Corrosion or Chemical Engineering from an accredited university. Page 9 of 10
Document Responsibility: Corrosion Control Standards Committee SABP-A-053 Issue Date: 23 August 2015 Qualification of Service Providers for Corrosion Next Planned Update: TBD Management Program (CMP) Deployment for Existing Facilities
15 years of experience related to chemical and water treatment in process industry; with at least 10 years in oil and gas industry. NACE Certified Chemical Treatment Specialist. Shall be responsible for addressing all chemical cleanin g and water treatment issues; works closely with proponent representatives on corrosion / chemical & water treatment / inspection / maintenance / operations issues.
4. Coatings Specialist (if required*):
Bachelor of Science or Engineering degree (or higher) in Materials, Corrosion, Metallurgical or Mechanical Engineering from an acc redited university. 15 years of experience in the evaluation, inspection and qualification of new and existing protective coating system; with a minimum of 10 years in upstream, downstream or offshore facilities of the oil and gas indu stry. NACE Certified Coating Inspector - Level 3 or Protective Coating Specialist. Shall be responsible for addressing all coating issues; works closely with proponents representatives on corrosion / chemical treatment / inspection / maintenance / operations issues.
5. Cathodic Protection Specialist (if required*):
Bachelor of Science or Engineering degree (or higher) in Electrical, Materials, Corrosion, Metallurgical or Mechanical Engineering from an a ccredited university. 15 years of experience in the design, evaluation, inspection and qualification of new and existing cathodic protection system; with a minimum of 10 years in onshore or offshore facilities of the oil and gas industry. NACE Certified Cathodic Protection Specialist. Shall be responsible for addressing all cathodic protection issues; works closely with proponent representatives on corrosion / inspection / m aintenance / operations issues.
Note:
The requirements of the specialties denoted by (*) is dependent on the type of the facility under CMP deployment, plant proponent request or central engineering request. The service provider shall verify in advance with the plant proponent and central engineering the need for these specialties prior to submitting his proposal.
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