QC Piping

QC Piping Inspector – Hand Book
With ARAMCO Engineering

Standard & Procedure
SHAHID ALI
Course Facilitator
CSWIP, API-570, B.Gas, NDT, ISO, IOSH, OSHA
Cell#: 00966-599-807084
Cell#: 0092-334-7497876
Email: ss_aakash@yahoo.com
Web: www.qctrainer.com
QC Piping Inspector – Course Outline
Sr No. Course Contents: Page No.
1 Project Scope of Work 2
2 Code, Standard & Procedure 2
3 Documents Review, PQP, Method of Statements 3
4 Materials (Pipe, Fittings etc) 3
5 Drawings (IFC Package) 8
6 Material Line Class 10
7 Service Line No. 12
8 Material receiving Inspection 13
9 Storage / handling & preservation 15
10 Pre fabrication inspection (Material, MTO, IFC etc) 21
11 Fit up inspection – Rolling 21
12 Welding (welding inspector scope) 21
13 Visual inspection (welding inspector scope) 21
14 PWHT (welding inspector scope) 21
15 NDT (welding inspector scope) 22
16 Release for Coating & Painting 22
17 Coating & painting(painting inspector scope) 22
18 Release to site 22
19 Spool receiving inspection 23
20 Erection 23
20 Fit up 23
22 Welding, Visual, PWHT, NDT 23
23 Valve installation 23
24 Flange joint inspection & Gasket Verification 24
25 Bolt Tightening & Torque 24-25
---- Guide lines for punch items categorization 26
26 Pre test punch listing – Line Checking (A & B Items) 27
27 Internal cleaning and flushing 27
28 Pressure Testing (Hydro & Pneumatic) 28
29 Lay Up 34
30 Punch List B Items – Pre Commissioning (PMCC) 35
31 Re- Instatement or Final Assembly Inspection (Final Punch List) 36
32 Clint Walk through (PMCC Punch List) 36
33 MCC 36
34 Tie In – Cold Cutting & SIS 37-39
QC Piping Inspector (www.qctrainer.com) – SHAHID ALI 2017-18
1- Project Scope of Work

Petrochemicals, Fertilizer, Gas processing plants, GOSP, Well Heads and Power Generation Plants.
2- Code, Standard & Procedure

ASME SECTIONS (American Society of Mechanical Engineers)
SECTION-1 Rules for Construction of Power Boilers

SECTION II Materials
Part A - Ferrous Material Specifications
Part B - Nonferrous Material Specifications
Part C - Specifications for Welding Rods, Electrodes, and Filler Metals
Part D - Properties (Customary)
Part E - Properties (Metric)
SECTION -IV Rules for Construction of Heating Boilers
SECTION-V Nondestructive Examination
RT (Article-2)
UT (Article-4 for Testing of Welds & Article 23 (Thickness measurement only)
PT (Article-6 All methods)
MT (Article 7 (Yoke & Prod Methods only)
SECTION-VI Recommended Rules for the Care and Operation of Heating Boilers
SECTION-VII Recommended Guidelines for the Care of Power Boilers
SECTION VIII Rules for Construction of Pressure Vessels Division 1, 2, 3
SECTION IX Welding and Brazing Qualifications
SECTION X Fiber - Reinforced Plastic Pressure Vessels
SECTION XI Rules for In service Inspection of Nuclear Power Plant Components
SECTION XII Rules for Construction and Continued S e r v i c e of Transport T a n k s .
ASME 31.1 (Pressure Piping, Power Piping)

ASME 31.3 (Process Piping)
ASME 31.4 (Pipeline Transportation Systems for Liquids and Slurries)
ASME 31.8 (Gas Transmission and Distribution Piping Systems)
ASTM - American Society of Testing Materials
A WS D 1.1 - American Welding S o c i e t y (Structural W e l d i n g )
A WS D l.6 - American W e l d i n g S o c i e t y (Structure S S Welding)
ASME B16.1 Cast iron pipes flanges & flanged fittings

Flanges ASME B16.5 Carbon steel pipes flanges & flanged fittings. (Up to 24”)
ASME B16.47 Large Diameter steel flanges. (Above 24”)
Butt welded ASME B16.9 Steel butt welding fittings
fittings ASME B16.28 Butt-welded short radius elbows & returns bends.
ASME B16.20 / API -601 Metallic gaskets for pipe flanges- Spiral wound
Gasket
ASME B16.20 Non metallic gasket
Socket &
Threaded ASME B16.11 Forged steel socket welding & threaded fittings
fittings
ASME B16.10 Face to face & end to end dimension of valves.
Valves Flanged & butt-welded ends steel valves (Pressure &Temperature
ASME B16.34
ratings) except Ball, Plug & Butter fly Valves
Complied & Written by: SHAHID ALI – KSA +966-599-807084 - PAK +92334 7497876 Page 2
3- Documents Review
Inspection & test plan (ITP)
Quality control procedure (QCP) – Method of Statement
Project specification i.e (ASME B31.1, 31.3, 31.4, 31.8 or API-1104)
Scope of Work / IFC Package
4- Materials (Pipe, Fittings etc) –Piping Design
FITTINGS:
1. Elbow To Joint the Two Pipe - Pipe Cut an Angle of
(Bends) 45 or 90 By Radius:
By Types: Short Radius
Equal Elbow Long Radius
Reducing Elbow Extra Long Radius
2. Tee Used to make a Branch Line at Right Angle to the Main line
Equal Tee
Reducing Tee
3. Reducer Normally where do we use the following?
i. Eccentric reducers
ii. Concentric reducers
Concentric reducer is used in pump suction. (Yes / No). Explain. Answer:

No. Air pockets may form if concentric reducer is used at pump suction, which results in
Cavitations, and cause damage to Pump. To avoid this problem, Eccentric Reducer with Flat
Side Up (FSU)is used in Pump Suction.
4. Olets OLET use for connecting Main Line to Branch Line

Small Sockolet
Bore Threadolet
Fittings Weldolet
Sweepolet
What are Weld olet and Sock olet, and where they are used?
Ans: Weld olet and Sock olet are basically self reinforced fittings.
Weld olet is used for Butt weld branch connection where standard tee is not available due
to size restrictions and the piping is of critical / high pressure service .
Sock olet is used for socket welding branch connection, which require reinforcing pad.
5. Valve Types of Valves
1-Check Valve (Non Return Valve)

Two Types: (Lift Check Valve, Swing check Valve)
Not Handle no need to operate: Installation Direction required
2-Ball Valve: 90o Angle required for Work
3- Safety Valve
4- Globe Valve: Installation Direction required
5- Butterfly Valve: Only move his Plate in 90o Angle (Both Side)
6- Gate Valve (No Direction required for installation)
7- Needle Valve
8-Pressure Control Valves -(PZV)
9-Pressure Relieves Valves. etc
Valves are classified based on its method of operation as: -

A. Self- operated valves. (Mainly the check valves are self-operated)
B. Operated valves. (all other valve types comes under operated valves.)
C-Motor Operated Valves- (MOV)
D- Piston Operated Valves -(POV)
Valves are classified based on end connection. End connection means arrangement of
attachment of the valve with the equipment or the piping.
Valves are classified based on end connection as: -

A. Screwed ends.
B. Socket ends.
C. Flanged ends.
D. Butt weld ends.
Value Materials
1- WCB Material on white capped body for CS.
2- CF&M for SS.
6. Gasket Gasket is a Ceramic Material Used to Fix Between Non-Metallic Gasket
the Flanges to avoid from leakage.
Asbestos Gasket
Metallic Gasket Rubber Gasket
Ring joint type – high (Orifice Plate) Tufflon Gasket
Octagonal Ring Gasket Lather Gasket
Spiral Wound Gasket
Pikotek Gaskets
Isolating Gasket (SAEP-351-03)
7. Strainers
8. Nipples Plain, Threaded, Swage
9. Saddle: Saddle use for taking connection from Main Line to Branch Line in 90o Direction..
& &
Lateral Lateral use for taking connection from Main Line to Branch Line other then 90o Direction.
10. Caps But weld Caps, Threaded Caps , End Caps
11. Coupling Full Coupling, Half Coupling, Threaded Coupling ,Reducer Coupling
12. Orifice (Flange- Plate) Orifice Flange Installation –(SAES-J-100)
Plates
13. Spacer Spacer is used for putting the Gap between Flange and Pipe where large dia of Pipe.
Pipe Flanges and types.
Base on attachment
1. Weld Neck Flange

2. Socket Weld Flange
3. Slip On Flange
4. Blind flange
5. Threaded Flange
Pressure
America Series:Class 150 ,Class 300, Class 600, Class 900A ,Class 1500,Class 2500.
Flange Facing Types

America Series:Flat face(FF),Raised face(RF),Tongue(T),Groove(G),Female(F),Male(M),Ring type joints
face(RJ/RTJ)
Material
√ Carbon steel: ASTM A105,ASTM A105N,GB 20,C22.8.
√ Alloy steel: ASTM/ASME A234 WP 1-WP 12-WP 11-WP 22-WP 5-WP 91-WP 911
√ Stainless steel: ASTM/ASME A403 WP 304-304L-304H-304LN-304N
√ ASTM/ASME A403 WP 316-316L-316H-316LN-316N-316Ti
√ ASTM/ASME A403 WP 320-320H ASTM/ASME A403 WP 347-347H
√ Low temperature steel: ASTM/ASME A402 WPL 3-WPL 6
√ High performance steel: ASTM/ASME A860 WPHY 42-46-52-60-65-70
Standards
ASME ANSI B16.5,ASME ANSI B16.47 & API 605,API 6L.
Industrial Processes
Die forging,Machining.
Application forSocket weld flange

Natural gas,chemical,petroleum,ship building,marine,paper making, metallurgy, electric, power, boiler , etc.
1- Weld Neck Flange
A weld neck flange is a type of steel flange designed to transfer

stresses to the pipe to reduce high stress concentrations at the
base of the flange. Compared with other types, weld neck flanges
are know for their tapered hub and gentle transition from flange
thickness to pipe wall thickness. They are deformation-resistant,
and are normally used for high pressure, high or low temperature
conditions.
Size
Weld neck flange:1/4"-160"
2- Socket Weld Flange
A Socket Weld Flange is similar to slip-on flanges, however, socket welds

have an internal recess on the inside diameter to allow for a smoother flow
of the process fluid. The positive of this is that is creates a smooth bore with
the proper welding and grinding. The negative of this type of flange is that it
can be more expensive than a slip-on due to more intricate machining, and
they can be less readily available than slip-ons due to the fact that the
bottom half of the inside diameter must be made to the same schedule as
the pipe that is being used. (you must specify the schedule needed) These
socket weld flanges were initially developed for use on smaller sizes of pipe
at higher pressure ratings.
Size
Socket weld flange:1/4"-4"
Slip On Flange
Slip on flange is a type of steel flange which slides over the end of piping and
then welded in place. Because the pipe slips into the flange before welding,
it has a low hub. The inside and outside of the flange are both welded,
resulting in sufficient strength and no leak.
Size
Slip On flange:1/4"-160"
Blind flange
A blind flange is a popular type of pipe flange. It has no bore in the center, and is
primarily used to close the ends of piping systems. This flange permits easy
access to a line once it has been sealed.
Size
Blind flange:1/4"-160"
Threaded Flange
A threaded Flanges is used for special circumstances with their main advantage
being that they can be attached to the pipe without welding. Sometimes a seal
weld is also used in conjunction with the threaded connection. This special type
of flange is generally used for high pressure, yet smaller diameter applications.
Obviously, the larger the flange is, the harder the ability to machine a thread
would be.
Size
Threaded flange:1/4"-6"
Code Of Pipe & Fittings

Item CS (Carbon Steel) SS (Stainless Steel) DS (Duplex Steel)
ASTM-106 ASTM-312 ASTM-790
PIPE
ASME-36.10 ASME-36.19 ASME-36.19
ELBOW
ASME-16.9 ASME-16.9 ASME-16.9
TEE
FLANGE
REDUCER
WELDOLET
THREDOLET
ASME-16.11 ASME-16.11 ASME-16.11
SOCKOLET
NIPPLE
ASME-36.10 ASME-36.19 ASME-36.19
CAP
ASME-16.9 ASME-36.19 ASME-36.19
Grade & Specification of

Items
API-5L Gr-B A 106 Gr.B API 5L X-60 API 5L X65 PSL2
PIPE API-5L Gr-B PSL-2 A 106 Gr.B API 5L X-60 API 5L X65 PSL2
NIPPLE API-5L Gr-B PSL-2 A 106 Gr.B API 5L X-60 API 5L X65 PSL2
FLANGE A 105 N A 105 N WPHY-60 ASTM A707 L3 CL3
OLT A 105 N A 105 N WPHY-60 ASTM A707 L3 CL3
VALE A 105 N A 105 N WPHY-60 ASTM A707 L3 CL3
ASTM X860 WPHY
FITTINGS A 234 GR-WPB A 234 GR-WPB A 234 GR-WPB
65
GUSSET
ASTM A516 GR-70
PLATE - - -
WEAR PAD - - - ASTM A516 GR-70
Grade & Specification
Items
API 5L GR X70 PSL2 ASTM A333 Gr.6 A 316L
PIPE API 5L GR X70 PSL2 ASTM A333 Gr.6 ASTM A312 TP 316L
NIPPLE API 5L GR X70 PSL2 ASTM A333 Gr.6 ASTM A312 TP 316L
FLANGE A707 L5 CL4 F10 A350LF2CL1 ASTM A 182 F 316L
OLT A707 L5 CL4 F10 A350LF2CL1 ASTM A 182 F 316L
VALE A707 L5 CL4 F10 A350LF2CL1 ASTM A 182 F 316L
ASTM A403 GR WP ASTM A403 GR WP
FITTINGS ASTM A860 WPHY 70
316L 316L
GUSSET
PLATE ASTM A516 GR70 - -
WEAR PAD ASTM A516 GR70 - -
Lateral / Reducer = Fittings Grade & Specification
5- Drawings
Types of Drawing
1. Isometric drawing. IFC – Issued for Construction.

2. P&ID-Piping Instrument Diagram
3. Plan Drawing
4. Views
5. Structure Drawing
6. Piping Arrangement Diagram.
Abbreviations use in P& Id

1. AT (Analyzer Transmitter). 2. AOV (Air Operated Valve).
3. DT (Density Transmitter). 4. ESD (Emergency Shutdown System).
5. FC (Flow Controller). 6. FCV (Flow Control Valve).
7. FE (Flow Manual Control Valve). 8. FG (Flow Sight Glass).
9. FMV (Flow Manual Control Valve). 10. FM (Flow Meter).
11. RO (Restriction Orifice). 12. FIC (Flow Indication Controller).
13. FR (Flow Reducer). 14. FT (Flow Transmitter).
15. HS (Hand Switch). 16. FY (Flow Relay).
17. LA (Level Alarm). 18. LV/LCV (Level Control Valve).
19. LG (Level Gauge Glass) 20. LIC (Level Indicator Controller).
20. LR (Level Recorder). 22. LI (Level Indicator).
23. PB (Push Button). 24. LS (Level Switch).
25. LT (Level Transmitter) 26. LTD (Level Transducer).
27. ML (Motor Status Light). 28. MOV (Motor Operated Valve).
29. PI (Pressure Indicator). 30. PC (Pressure Controller).
31. PS (Pressure Switch). 32. PX (Pressure Point).
33. PT (Pressure Transmitter). 34. PZV (Pressure Control Valve).
35. SI (Speed Indicator). 36. RTD (Reset Temperature Detector).
37. TCV (Temperature Control Valve). 38. TE (Temperature Element).
39. TV (Temperature Control Valve). 40. TW (Thermo Well).
41. TTD (Temp. Transducer). 42. TT (Temp. Transmitter).
43. TO (Thermometer). 44. THS (Temp. Hand Switch).
45. TI (Temp. Indicator). 46. TR (Temp. Recorder).
47. TS (Temp. Switch). 48. TT (Temp Transmitter).
49. PCV (Pressure Control valve). 50. PDI (Pressure Differential Indicator).
6- Line Class:- (SAES-L-105)
3CS1P11
First = Pressure rating
Second = Pipe Material
Third = Corrosion Allowance
Forth = Service
Fifth = Modification Suffix – Optional
An example of a complete piping line class designator is "3CS1P11". This designator specifies an
ASME pressure class 300, carbon steel piping system with 1.6 mm corrosion allowance designed for
general process service & fifth field is optional Project Specific requirements.
Exceptions, modification, or additions may be made to the base piping line class to meet specific
requirements through the use of the fifth field location, i.e., modification suffix. Line classes
with listed fields shall be approved the Chairman of the Piping Standards Committee.
1. CB (Chilled Carbon Steel).

2. CC (Low Carbon Steel)
3. SX (Duplex Stainless Steel).
7- Different Services Of Lines
A (Air). H (Hydrogen).
BBD (Boiler Blow down). HCL (Hydrochloric Acid).
BD (Blow Down). HO (Hydraulic Oil).
BFW (Boiler Feed Water). HSG (Hydrogen Sulfide Gas).
C (Chemical). IA (Instrument Air).
CA (Caustic). LO (Lube Oil).
CAS (Caustic sewer). PA (Process Air).
CS (Chemical Sewer). RL (Relief Line).
CW (Chilled Water). RW (Raw Water).
CWR (Cooling water return) S (Steam).
CWS (Cooling water supply) SA (Sulfuric Acid).
DMW (Dematerialized Water) SF (Sulfur).
DSW (Distilled water). SR (Sewer Storm).
DW (Drinking water). SW (Salt Water).
EIA (Emergency Instrument Air) SWS (Sanitary Sewer).
FG (Fuel Gas). TW (Treated Water).
HGH (High Pressure Fuel Gas) UA (Utility Air).
FGL (Low Pressure Fuel Gas). UW (Utility Water).
FLO (Flushing Oil). W (Water).
FW (Fire Water). WW (Waste Water).
8- Material Receiving Inspection
The store keeper / ware house supervisor will receives materials at site/ Lay down Yard
The delivery note, packing list, materials quantity will be cross checked by store keeper against
Purchase Order.
The offloading of materials will be done as per handling procedure provided by manufacturer (for
special & critical materials)
SATIP-L-350-08 SATIP-L-450-04
(For Laydown – Plot Piping) (Pipe Line Project)
1- Purchase Order (PO)
2- IRN, IRC
3- Delivery Note (DN)
4- MTC
5- MSDS (Material Safety Data Sheet)
6- SIS (Safety Instruction Sheet)
7- Tally Sheet (All Details Computerized)
8- PMI – (Specific Material for Chemical Composition Confirmation)
9- MTO – IFC (Optional) as per Project Requirement
Meet the minimum requirements of Sch Q, Att. III, Para. 3.22
Inspection Level:-
As per SAER-175 Form establish minimum inspection and testing requirements for procured inspect-
able material and equipments.
Level-0 Documentation requirement only; no vendor inspection required.

Level-1 Only final inspection is required prior to shipping
Level-2 Includes, as a minimum, pre inspection meetings, one or more unspecified in progress surveillance
/ visits, all witness and hold points, final inspection and release for shipment
Level-3 Same as Level 2, except that in progress surveillance shall be on regular basis (Daily, weekly or Bi-
weekly)
Level-4 Resident Inspector continually monitoring the work.
SAMSS (Saudi Aramco Materials System Specifications)

Requirements for Material Receiving:-
Seamless Pipe or Welded Pipe: (Straight/ Spiral)- SAW

Pipe: 01-SAMSS-035 & 01-SAMSS-038
Fittings: 02-SAMSS-005
Flange: 02--SAMSS-011
Bends: 01--SAMSS-039
All 02-SAMSS-011 materials may be used wet sour service.
Valve: (04-SAMSS-035 General Requirements)

Gate Valve: 04-SAMSS-001
Globe Valve: 04-SAMSS-002
Low Temp Valve: 04--SAMSS-003
Check Valve (Swing Type):04-SAMSS-005
Initial Inspection and Examination
Upon receipt of the material or equipment at site, the material controller unloads the
material or equipment in the designated material receiving area.
The delivered items shall be verified against delivery documents and along with the delivery,
shall verify the traceability documents supplied with the delivered material or equipment,
ensuring that the documents are complete including supplier inspection release, Test
Reports, Mill Test Certificates, etc.
Ocular inspection on the material or equipment is conducted by the Material Controller to

ensure that products comply with requirements, quantities are correct, and products are
undamaged.
Verification of Associated Documents (SAIC-L-2005) – SATIP-L-350-01 & 08

The material/equipment supplied to site shall include the following documents;
• Copy of Purchase Order (PO)
• Delivery Notes and/or Invoices
• Final Inspection Release Note from Manufacturer
• Equipment Operation and Manuals and Vendor Supplied Drawings
• Delivery Packing Lists
• Manufacturer’s Instruction Sheets
• Material Safety Data Sheets
• Mill Test Certificates etc….
Purchase order Information
√ The applicable code (ASME B31.1,B31.3,B31.4 or B31.8 )

√ Detailed Isometric Drawing or Piping Detail Sheets.
√ Service conditions.
√ Post-weld head treatment, if required by service conditions (otherwise, it shall be the
governed by the applicable code.
√ Materials to be supplied by the vendor.
√ Materials to be supplied by the Buyer to the Vendor, if any.
√ Inspection requirements- Form 175-013100 plus any additional requirements.
√ Minimum I.D. dimension, if required to permit passage of instrumented scraper or
maintenance scraper.
√ Impact testing requirements.
√ Non- material Requirements (NMR) form for fabricated pipe bend (s) if applicable.
√ Surface preparation and paint for coating requirements.
Transportation and Handling

Products shall be transported and handled in accordance with manufacturer’s instructions or
Saudi Aramco requirements as applicable.
Equipment and experienced personnel shall be provided to handle products by methods to

prevent soiling, disfigurement or damage.
If discrepancy, shortage or damages are found, this will be reported to the procurement manager for
further action and coordination with vendor, supplier or manufacturer, or transportation agency
(where applicable), and material with discrepancies will be sent to the quarantine area
The material/equipment will be sent to the warehouse or site area with maintained inventory from
the Warehouse Supervisor.
Original and distribution copies of signed-off Material Receiving Report including attachments will be
provided to Document Control/Project Files, Procurement Manager and Material Receiving
Coordinator for further action.
Notice to Inspection (NTI)- Internal RFI

The MRR (Material Receiving Report) will be prepared by Store Keeper / Warehouse supervisor and
submitted to Procurement Manager and Material Receiving Coordinator with all relevant documents
and accomplished copy of Notice to Inspection (NTI) with desired date and time of inspection.
The material receiving coordinator will do the internal material receiving inspection along with
discipline QC inspector by checking transportation damage, storage as per discipline, the cartons,
crates, crafts or packing materials will be checked for any damage or physical defect etc. And prepare
MRR (Material Receiving Report)
The material received must have stamped or stencilled the manufacturer name, material grade, heat
number, size, schedule / pressure rating, and colour code for the gaskets.
The RFI for material receiving at site will be raised by relevant disciplined QC inspector with
coordination of material receiving coordinator
Once material accepted by the CLIENT, the materials are ready for installation and construction
activities.
Material request form shall be submitted to store keeper by construction team who ever need the
material for installation and upon satisfactory acceptance the materials will be released by store
keeper
The inventory shall be maintained by store keeper and should submitted to procurement manager
on weekly basis
Store keeper should maintain the storage yard by following manufacturer instructions/ guide lines /
procedures
The material receiving inspection report serves as the instrument for receipt of material and
equipment and also serves as the quality control inspection report.
Non Conformance Materials
Nonconforming products registered at receiving inspection at site shall be marked as nonconforming
and segregated to specific area for products not conforming to purchase order and/or quality
requirements.
Materials received without documents such as release note, acceptance certificate etc. shall be
marked and stored in the area for nonconforming products.
Materials stored in the area for nonconforming products shall be reported to the procurement
manager – using “over/short/damage report”, who shall take action to correct the nonconforming
products stored in the specific area.
NCR shell be issued in accordance with QAP-11, Rev. 00.
Request for Inspection (RFI)

Prior to upon completion of specific work activity or material/equipment arrival to site
considered as typical inspection point, Request for Inspection (RFI SA-6717 Form), shall be
submitted to SAPID through SAPMT concerning, material receiving, construction and
installation work activities considered as typical inspection points.
The CLIENT will be informed of the material arrival at site and the RFI will be raised by the
relevant QC inspector with concurrence of QC Material Receiving Coordinator. The relevant
documents like applicable SAIC and SATIP will be attached with vendor/manufacturer
documents. The time and date will be mentioned in the RFI and the CLIENT will inspect and
sign off the RFI if the materials are accepted.
Material Storage
Accepted materials shall be logged into the material inventory system and stored, either at
the Store or Lay down area, depending on the size and value of the materials.
Steel materials shall be stored on cross-timbers or concrete slab.
All process and utility piping materials shall be stored with end cap or cover.
All material shall be stored as per Material Receiving - Storage - Handling & Preservation (SK-
QAP-10 , Rev. 00)
The materials storage on Lay down areas shall be based on:
Material Specification, Grade, Etc.

Material Size.
Material Type – Pipes, Flanges, Elbows, Beams, Channels, Angles, etc.
Civil materials shall be stored on separate Lay down areas.
Materials storage shall be in an easily identifiable manner.
√ Flammable materials shall be stored in a separately marked area with adequate caution notices.
√ Equipment stored at the Lay down area shall be well protected against weathering conditions, as
per manufacturer’s instructions.
√ Non-metallic conduits, pipes and fittings (thermoplastic and RTR) shall be stored as follows:
√ Pipe shall be stored out of direct sunlight in a building or under a cover that allows free air
circulation.
√ If loose pipes are stacked on each other, the stack height shall not exceed 1.5m. Adequate side
along supports shall be provided to prevent slipping or rolling.
√ If pipe is stored on rocks or bearing boards, the supports shall be at least 75mm wide. Supports
shall be spaced on 3m centers maximum with the first 1.5m from the end of the pipe.
√ All supporting surfaces shall be free of sharp objects.
√ Fittings shall be stored in the original containers and shall be kept in a building or under a cover
that allows free air circulation.
√ Gaskets shall be stored flat on racks below 38°C and out of direct sunlight.
√ Adhesive for RTR piping shall be stored in an enclosure where temperatures do not exceed 38°C.
√ Pipe and fittings shall be properly protected from impact, especially on their ends. They shall not
be thrown, dropped, bumped, hit, or dragged and pushed over abrasive surfaces.
√ Loose thermoplastic or RTR pipe shall be handled by hand or if the pipe is too heavy, using nylon
or cotton strap spreader slings.
√ In case of any damage or deterioration occurred to the material during handling or, storage,
Material Engineer makes a request to the QC Inspector for an inspection. Necessary corrective
action is taken with the co-ordination of the QC Inspector or concerned department head.
Material Traceability
The material after receiving inspection will be tagged and labeled according to the following:
1. Accepted
2. Rejected
3. Quarantine
4. Damaged – for repair or replacement
5. Scrap – not for repair and replacement required
6. Hold – for clarification with procurement department
The material after receiving will be checked by material receipt, the quality of identification and
traceability of all vendor & supplier items.
Traceability will be further ensured by the certificates of the materials supplied by the manufacturer
indicating chemical analysis, test results and heat numbers of main items.
The identification and traceability will be ensured under the responsibility of the QA/QC department
using the welding book, the weld tracking log and the material certificates.
9- Material Handling, Preservation and Storage

Storage & handling or preservation (Ref: SAIC-L-2034, SATIP-L-350-08)
All materials are handled with care during fabrication and installation to prevent damage.
Pipe is not be stored directly on the ground, Pipe shall be placed on mounds or sleepers
Stacking of pipes is made in a manner to avoid damage to pipes or coating.
Fittings and valves are stored in shipping crates or on racks.
End protectors on pipes, flanges, weld bevels, threads, and socket ends, are firmly attached.
Stainless steel material is protected against exposure to seawater splash during shipments.
If the pipe is coated, tight Nylon rope outside diameter both end of the pipe.
Lined and coated pipes and fittings are lifted with wide fabric or rubber-covered slings, and
padding is used to prevent damage to lining or coatings.
Pipe shall not be stored directly on the ground. Pipe shall be placed on mounds or sleepers.
Stacking of pipes shall be made in manner to avoid damage to pipes or coatings (SAES-H-200)
Fittings and valves shall be stored in shipping crates or on racks.
End Protectors on Pipes, flanges, weld bevels, thread, and socket ends shall be firmly attached.
CS and galvanized pipes shall be stored separately.
During off loading, pipes shall not be dropped on the transport, a crane and suitable certified
slings shall be used. Nylon slings will be used to handle coated piping and fittings.
The assembly of bolted flanges joints shall be in accordance with SAEP-351
Pipe shall not be rolled or dropped off trucks
Internally coated pipe shall be handled from the outside Diameter only.
Slings for lifting pipe shall be nylon similar material to prevent damage to the pipe surface. Wire
rope slings are not to be used.
One RFI every week for PID verification
Material Preservation
The material shall be preserved as per manufacturer recommendation. Preserving materials by
maintaining proper temperature and inside storage such as Chemical materials, Paint, Electric delicate
materials.
Material Storage:
The storage facility can be categorized in 3 ways:
1) Proper storage for bulk materials (like pipes, fittings, cables, structures etc.).
2) Proper storage for ESD materials (Electro Static Device) i.e communication and electric
materials/equipment
3) Quarantine Area.
Storage for Bulk Materials:

For bulk materials the storage should be spacious, free for handling and shall be sheltered as per
manufacturer recommendation.
Storage of ESD Material

ESD sensitive material should be stored in containers or covered shelters with proper lighting, air
conditioning by maintaining room temperature as per manufacturer recommendation.
Quarantine Storage Area:
This area should be meant for such materials:
• Materials which are damaged during transportation

• Material which are damaged during handling
• Materials which are excess from manufacturer against purchase order quantity
• Materials which are rejected during RFI
• Material which are supposed to be returned back to manufacturer
Material Issue
Materials required by each discipline shall be requested by the respective supervisor or foreman
thru the Material Requisition Form (MRF).
Availability of the material requested shall be verified and available materials shall be released by the
Storekeeper or Material Controller by accomplishing the Material Issue Form (MIF).
Transaction made for the day shall be updated on a daily basis.
Inventory shall be regularly verified against physical count and maintained on all materials in stock.
Material Usage
All care shall be taken to prevent damage to the materials, while in use.
Items found damaged or unsuitable during installation, shall be:
Immediately reported by the Site Supervisor/Foreman to the Material Controller, who will in turn,
notify the Quality Department.
Replaced, unless modifications, or repair, can be satisfactorily demonstrated to Saudi Aramco

Representative.
All received material shall be documented in the weekly material receiving summary log.
Material Issuance and Inventory

Material Issuance Reports shall be prepared to account for all material and equipment
requested by and issued to the Construction or Installation team or Subcontractor throughout
the construction period.
The Material Issuance Report will identify to whom the issue is made (requester), location of
issue, quantities and brief description of material or equipment issued, and signatures of the
material requester, material specialist/storekeeper making the issue and the responsible
personnel for the receipt.
The material requester will initiate to fill out the materials required for installation or
construction work. The filled out form will be routed and forwarded to the material person or
storekeeper to prepare the materials requested.
The material personnel or storekeeper assigned to the warehouse (logistics) is responsible for
the preparation and accounting of materials issued during construction and installation.
Completed material issuance reports are kept on record by the Material Personnel or
Storekeeper. A copy of the material issuance report will be provided to the document controller
for filing.
The Material Issuance Reports will indicate the name of the representative responsible for the
receipt.
The Warehouse Supervisor/Store Keeper should keep and update the material inventory record
with the “Receipt, Accept, Stock, Issuance& Balance Details” The Warehouse Supervisor/Store
Keeper should report to the procurement Manager by providing weekly inventory report so that
the Procurement Manager could report the status to the CLIENT.
Type of material use accordingly to temperature?

SAES-L-109: Selection of Flanges, Stud Bolts and Gaskets
10- Pre-fabrication
Pipe cutting list – transfer heat No. to the cutting pipe.
Ensure that no debris inside the pipe.
Dimension & Visual for any damage.
11- Fit – up (Ref: SAIC-L-2035, SAESL-350) & (SATIP-L-350-08)
Pipe specification, latest revised ISO, MTO, MTC, Heat No, Classification, Grade &
Specification, diameter, schedule, rating, joint No., spool No., drawing No. (ISO) &
WPS No.
Straightness, plumbness, parallelism. Face of face gap, Bevel end, and root face as
per WPS.
Orientation.
Buffing not less than 1” inside and outside.
Contractor has prepared detailed shop fabrication drawings, and the
Latest approved Revision of these is available at work place.
Mitered joints are not permitted.
Pipe ends and pipe spools to be joined by girth welds during field.
Installation, are prepared and matched to facilitate fit-up in the field.
Welding ends are beveled with an angle of 35 degrees + 5 degrees, and with a 1.6
mm root face.
Rotation of flanges, measured as the offset between elevations of bolt holes on
opposite sides of a flange centerline, shall not exceed ± 2.4 mm.
The tilt of a flange measured at the periphery across any diameter shall not exceed
1.6 mm from the square position.
Flange face separation, gasket thickness : ± 1.6 mm
Flange bolt holes shall straddle the established centerlines.
12- Welding (welding inspector scope) (ASME SEC IX, SAES –W-11 or W-12)
Before welding
During welding
After welding
13- Visual inspection
Ensure that all material (spool) free from damages.

Ensure no foreign materials like hand gloves, debris etc. Inside the pipe.
14- PWHT (welding inspector scope)

Furnace
Local
15- NDT (welding inspector scope) (ASME SEC-V, SAES – W-11 or W-12)
VT, RT, MT, PT, UT
16- Spool Release Inspection for Painting - IRC

Provide the tags for completed spools as per isometric drawing which contents spool
number for easy tracking
Verify that all the welding joints are completed prior to release and visually inspected for
any visual defect.
All the NDE requirement shall be completed including the repair activity prior to release.
All the spools shall be tagged with identification prior to shipment.
17- Coating & painting (painting inspector scope) (SAES – H- 1002)
Coating & painting to be done (if required).
18 - Spool Release Inspection for Site - IRC

Open ends of pipeline strings shall be capped to prevent entry of debris or animals and
birds.
Provide the tags for completed spools as per isometric drawing which contents spool
number for easy tracking
Verify that all the welding joints are completed prior to release and visually inspected for
any visual defect.
All the NDE requirement shall be completed including the repair activity prior to release.
Open ends shall be end capped and flange ends shall be protected with plywood.
All the spools shall be tagged with identification prior to shipment.
Girth weld Cut back area shall not be coated prior to hydro test.
Release note shall be filled and signed by the relevant QC prior to shipment.
Ensure that the all spool shall free from damages.
Coating shall not be removed during shipment.
Visual inspection & spool inspection as per ISO drawing.
Fitting have the material specification & Grade, heat No., Stamp on it, with proper color
code.
Spools have stenciled their spool No., ISO sheet No.
Ensure that the all related documents, like MTC, ISO latest revision, coating report, weld
summary, NDT certificate if applicable with approved and signed with client to all
documents.
All material shall have the plant or project code No.
All material tracking as per shipment if missing, segregated or control and trace.
19- Spool Receiving Inspection for Site
Ensure of All above Bullet Point during receiving inspection of fabricated / painted Spool.
20- Erection
During assembly and erection, the construction agency shall ensure, That no foreign
materials (such as welding consumables, lumbers, Gloves, etc.) are left inside the piping
system.
Stencil – Clearly make with permanent marker.
Color code or permanent tag- for easily identified.
Damage - Ensure that spool not damage during installation.
Centerline run pipe – Ensure the line shall be straight.
Slope – Ensure the pipe slope maintain as per ISO drawing
Elevation – Ensure elevation of pipe is correct point
Cleanness – Ensure all spool or pipe chemically clean or air blow and free from foreign
materials.
Supports – Support will bear the load of pipe, and unlevel support repair to insert shim.
Conformance of piping system installed as per drawing.
Horizontal and vertical rolling.
Location of all piping parts as indicated on the drawings.
Branches are reinforced and located correctly.
Vents and drains are properly installed
Reducer type and location are correct
Blinds are installed
20- FIT – UP
♦ Ensure that the pipe is parallel, straight & plumping.
♦ Check the dimension as per ISO Drawing.
♦ Correct spool using as per ISO drawing.
♦ Material using as per ISO drawing.
♦ Ensure the elevation of pipe is correct as per ISO drawing.
22- Welding /NDT/ PWHT
23- Valve Installation

Saudi Aramco Engineering Standard (SAES-L-108) for Selection of Valve, Acceptance, Ranges etc
API Standard for valve testing is API-598
• Valve shall be clean ensure that no foreign material inside the valve.
• Union bonnet values are not use in any hydrogen service.
• Ensure the indication of valve (arrow) toward the flow.
• All thread connection on valve bodies shell be seal weld.
• Valves are adequately installed in relation to the direction of flow.
• The handles are oriented as shown on the drawings and whether there is any inconvenience
in the operation.
• The valves provided are of the specified symbols.
24- Flange Joint Inspection
Flange to be installed shall meet the requirement of SAES-L-109
Ensure that the flange material correct as per ISO size, rating, dimension as per B16.5,
B16.47 &visual.
Inspection for misalignment, parallelism, plumbness, straddleness (vertical, horizontal, bolt
hole offset 2.4mm.
Gasket verification – free form damage, colour code for relating on the rim.
SAES-L-105 is standard for Gasket Selection may also be verified for compatibility with the
flanges line classification)
Bolt shall be free move in flange hole.
Bolt sequence tightening
Calibration of bolt torque wrench
Material of nut & bolt as per ISO drawing.
Ensure the bolt torque value as per B16.5,B16.47
The flange joint assembly and bolt tightened in accordance with SAEP-351
The adequacy of the length of bolts.
Bolts to be used are as specified and bolting is uniform.
Flange rating is correct and packing faces have been cleaned.
Gaskets are specified and the contact of the gasket around the entire circumference is
satisfactory.
The packing paste is appropriate.
The packing are new and are of the specified material and thickness.
The flange face shall protect with wooden cover after welding.
Installation of Flanged Joints
All flanges shall be fitted so that the flanges face bears uniformly on the gasket and bolts experience
uniform stress when tightened.
25- Bolt Tightening Sequences (SAEP-351)
All flanges shall be aligned with bolts staggered on equal distance from the vertical and
horizontal flanges center line (i.e. two holes).
Stud bolts shall extend nuts Stud bolts and nuts shall be cleaned and greased prior to
installation. Studs extending more than three threads shall be protected with a plastic pipe
sleeve and I or pipe cap.
Bolt tightening procedure and sequence refer to SAEP-351.
Bolts shall be tightened to 30% of the recommended bolt stress, and then tighten all the
bolt tension and torque necessary to off-set hydrostatic test pressure or 50% minimum yield
of the bolts whichever is greater.
For flanges made up of using conventional method, each bolt shall be checked with a
calibrated wrench or other suitable equipment to ascertain bolts are evenly and uniformly
stressed.
All gaskets shall be properly composed in accordance with the design principles applicable to
the type of gasket used.
GUIDE LINES FOR PUNCH ITEMS CATEGORIZATION
Test Pack Preparation

Pre-Test Punch Listing
Clear 'A' Items
S. Aramco Pre-Test Punch Listing
Clear S.Aramco 'A' Items
Flushing & Cleanliness
Pressure Testing
Lay-Up
Reinstatement (Final Assembly)
Clear 'B' Items
S. Aramco Final Insp for MCC
Definitions:
Category Punch 'A' Items : Items to be completed prior to Pressure Test (Hydro/Pneumatic) & Service.
Category Punch 'B' Items : Items to be completed after Pressure Test (Hydro/Pneumatic) & Service.
Note :
1. Initial puch list shall be carried out by contractor prior package submission to SAPMT &
SAPID. SAPID will list additional punch items (If not listed by contractor/SAPMT) for
Category A & B items.
2. The purpose of this sheet to provide you the guidelines for punch list categorization and
not listed all the requirements of standards and international standards. It is user
responsibility to verify the standard requirements and shall not limited to below
categorized items.
3. Visual test packages like open vent and drain lines shall not have any punch B' Items
and All items shall be listed for Category A' Items.
26- Pre test punch list (“A” items)

Verify the whole line to be installed as per the Bill of Material of the latest &
Approved ISO Drawing.
External coating & priming of joints is allowed only if approved by Inspection
Department Mgr & proponent Organization Representative.
Vent & drain conforms.
Supports are installed with bear the load of pipe during hydro.
Straightness, parallel, plumbness, elevation at correct position.
All thread joint shall have proper light only 3 to 4 thread shall visible.
Valve installed in thread line shall have seal welded.
Temporary support welded or without welded wave ground off.
Field test valve shall have been field tested prior to hydro test & certificate attached
in the package.
Weep hole shall be provided(6 mm)
All flange inspection shall be completed as per specified procedure.
Spare taps of orifice flange are plugged and seal welded.
All permanent flange joints were inspected, gasket material verified & properly
torqued. (Review Flange joint report, SAIC-L-2014)
Ensure that all weld joint, NDT, PWHT, hardness if specified has been completed.
Vents and drain valves, both temporary and permanent, conforms to the piping class
or rating. (Refer SAES-L-108)
Supports are installed. Additional temporary support may be installed as required.
Expansion joints and spring hangers or spring supports are provided with temporary
restraints.
Arc strikes, gouges, and other indications of careless workmanship (such as surface
porosity, uneven weld profiles, and undercut) shall be removed by grinding and
inspected by magnetic particle or liquid Penetrant method.
All in line valves that are not used as test isolation valves are in open position.
Isolation valves are verified to have been body and seat tested prior to installation
through verification of field test certificates.
All threaded joints up to the first block valve of hydrocarbon pipeline are seal
welded. Thread engagement has been verified & accepted.
Disc of check valve is removed, unless check valve has by-pass.
Test Package Review:
i. Missing of Test Package contents as per SAEP-1160.
ii. Wrong/Missing information on Test Package Documents..
Example : Wrong test limits on P&ID and Isometric Drawings, Wrong test pressure reflected on test
package contents compaired to P&ID, Old revisions of drawings attached to test package, Pressure
calculations are not as per SAES-L-150 and Missing of test pack documents like weld summary, NDE
Reports or not cleared per line class etc.
NDE is not completed as per the line class for 10% & 100% lines
Repair of weld joint is not yet carried out within the test limits.
Valve test reports for inline valves
Verification of internal grinding reports of Orifice flanges as per 10.4.2 of SAES-L-350.
27- Internal cleaning and flushing (SAES – L-350)

Progressive Internal inspection during assembly by visual or use of video inspection
techniques.
Water Flushing.
Pneumatic Flushing.
Pressurized Air Shock Blowing (PASB).
Mechanical Scrapers.
Visual
HYDRO TEST PACKAGE CONTENTS
28. Final Hydro testing
CV = Check Valve
PZV / PSV = Pressure Relive Valve / Pressure Safety Valve
PG = Pressure Gauge
TB = Test Blind
Design Pressure
Design pressure is the condition of real-time temperature and pressure that is expected in a normal
condition.
Test Pressure
Design pressure is the maximum pressure that the system that can be exposed to and sets the
system relief valve at the same pressure.
MAWP
Maximum Allowable Working Pressure is the maximum pressure that is permissible at the top of the
equipment or vessel in normal operating conditions.
Design Pressure (Greater Then or Equal to) MAWP (Maximum Allowable Working Pressure)
Design Pressure (Greater Then) MOAP (Maximum Allowable Operating Pressure) 10% to 25%
But :
MOAP is less than MAWP
Design pressure should be below MAWP and based on company standards can vary from 10% to
25% above the maximum operating pressure of the system (MAOP)
The PSV set pressure is based on design pressure, and it can be equal to the MAWP but not higher.
1. How to calculate design pressure

D-(DF) x (smys) x (2tc) / (OD) – Hoop stress….
1.5 times
2. Minimum – Test Pressure
2x0.9yt \ D
Y = specified Min. yield strength of pipe material
T = Normal pipe thickness x 0.875
D = outside dia of pipe
Examples:
2x [0.9 x 35000 x 0.280 x 0.8751] 6.625
= 9330 psi
1-General requirements for test manifold:-
"Approved" Pressure Test Procedure.
Pressure Test Diagram which shall include the limits of piping (including test
manifold) and equipment included in each pressure test, high points and low points
(drain), locations of pressure gauges, test pressures, test temperature, test fluid, line
flushing requirements, and safety precautions.
NDT accepted of test Manifold of all joints.
Relief valve, manifold, pressure gages and recorders calibration records.
Pressure gauges and pressure recorders are calibrated within one (1) month before
the test. Check stickers at eh time of the test.
When large systems are tested, Inspection personnel will determine the need for
additional gauges.
Company Safety Instruction Sheet (for critical piping) and Pressure Test
(G.I.002.102).
Copies of P&ID and isometric drawings of the piping system to be pressure tested.
Piping spools control sheet with NDT extent and results.
Pre-pressure test check List.
Test manifold hydro test verification.
Recording gauges shall be used where it is necessary to keep a Permanent record,
e.g., when the test duration exceeds four hours, or otherwise as required by this
standard.
Expansion joints and spring hangers or spring supports shall be provided with
temporary restraints where needed to prevent excessive travel or deformation
under the test loads.
The test fluid shall be injected at the lowest point in the system to minimize
entrapped air.
Vents shall be provided at all high points of the piping system.
2-General requirements for pressure gauges and recorders:-
Calibration valid Period:-
Pressure Gauge – one month (30 days).
Relief Value – 07 days.
All gauges shall have a range such that the test pressure is within 30 to 80% of the
full range.
Pressure rating or design of test manifold components (isolation valves, pipe,
nipples, and fittings) exceeds system test pressure by 20%.
A minimum of two pressure gauges are required for the test System. One pressure
gauge shall be on the test manifold and the Other(s) on the test system. Their
accuracy shall be within 5% of One another.
When testing large system inspector can determine for more gauges.
Recording gauges should be used when permanent record is required.
3-General requirements for test relief valves:-

Calibration valid Period:-
Relief Value – 07 days.
• Relief valve is located in the system under test and near the test pump with isolation
valves on the inlet and outlet of the relief valves sealed open during the test.
• Relief valves of adequate capacity are set to relive at 5% above the hydro test
pressure.
• Relief valves are testing, dated and tagged (as valid) for a period of one week for
project pressure test. Stickers are legible & valid.
• The requirements of field testing of valves shall be as per SAES-L-108.
• Relieve valve will be set at 5% above the test pressure if the test pressure is up to
85%.
• More than 85% test pressure relieve valve will be set 10%.
• An isolation valve will be provided between the manifold and system being tested.
After the test pressure is reached and before commencement of inspection of the
system, the isolation valve between the temporary test manifold/piping and the
piping/equipment under pressure test shall be closed and the test pump
disconnected.
The isolation valve downstream of the manifold shall be opened after the pump is
disconnected.
A blow down valve of adequate pressure rating is installed to depressurize the system
safely.
In short:
3. Test pressure – 1.5 x Design Press.
4. The pressure testing manifold is separately pressure tested to at least 1.2 times or
20% Above the system test pressure (Hydro Test) (SAES-A-004 Para 5.54)
5. All Nipple are CS & minimum Sch-80
6. All Fittings shall be CS & minimum Sch-60
7. Press Gauge selection - 30 to 80% [range with limit]
8. Relief value testing pressure – 5 to 10% hydro press test
9. Two pressure test required minim
- One should be in high range [near to vent]
- Another should be in manifold.
10. Manifold Consist of
1. Non-Return value / Gate Valve
2. Drain
3. Pressure gauge
4. Relief value
Test Certificate Validity / Calibration

5. Manifold – 1 year (Project Specification Some Code 5-Years)
6. Pressure Gauge – 30 days (1month ) – 2No’s
7. Relief Value – 07 days.
Water Analysis and Requirements for Hydrotest:

In SS Pipe we use DM Water only
DM – De Mineralized Water
Example: chlorine – 50ppm (min)
Ph value – 7 to 12
[Because to avoid the reaction with chromium in SS]
In CS we use sweat water (normal water).

Water used for any part of the hydrotesting or subsequent lay-up shall have a
sulfate reducing bacteria (SRB) count of 10³ (1000) per ml or less as determined by the
RapidChek II Method or alternative test method approved by Supervisor,
CTU/ME&CCD/CSD. Water that has a higher bacteria count may be accepted at the
discretion of the Supervisor, CTU/ME&CCD/CSD, after treatment with biocide and retesting.
Don’t Use:-
SRB count is greater than 1000 per ml / Water Oxygen level less than 20ppb
Dematerialized Water : Chloride Contents shall be below 50mg/l
4-General requirements for Filling & Pressurization:-
• Filling & pressurization is done upstream of check valves in system. Test fluid enters
(shall be drained) at the lowest point in the system. All vents are open during filling.
Minimize trapped air.
• Remove air during filling by the following measures:
A) Design /Plan Tests. Provide high point vents.
B) Mechanically (Use scrapers as needed to remove air).
C) On initial pressurization, pressure holds AFTER equalization at
50% test pressure. Gauge drops indicate a leak (acceptable for
efficiency) or inefficient test crews leaving air in line
(unacceptable).
• After venting, valves used for venting are placed in the partially open position and
plugged or blinded as applicable.
• Preliminary check for leaks at 50% of the strength test pressure was performed. Test
crews were efficient in filling practices.
• Pressurization will be done slowly and gradually.
5-General requirements for test pressure & duration for pressure testing of
pipelines?
• Lube and seal oil piping shall be pressure tested with its own fluid. The test pressure
shall be 1.5 times the design pressure or 690 kPa (100 psig) whichever is the greater.
Test duration shall not be less than 30 minutes, to determine that there are no leaks.
Where : (1psig = 6.894 kpa)
• Underground process piping shall be tested prior to backfilling. The test pressure
shall maintain for a 4 hrs. If for justifiable safety reasons the line must be backfilled,
then the joints shall remain exposed during testing, otherwise the test shall be a 24
hour recorded test.
• Flare lines 24-inch NPS and larger with a design pressure of 517 kPa (75 psig) or
lower may be pneumatically strength tested in accordance with paragraph 345-5 of
ASME B31.3.
• Piping in vacuum service shall be pressure tested to 1.5 times the differential
external pressure not less than 100 kPa (15psig). Test duration shall not be less than
30 minutes, to determine that there are no leaks.
• Plant utility piping in air & Inert gas services with designed pressure & Equal to less
than (150 psig).
• Low pressure steam piping designed for 60 psig or less.
• Piping such as drains vents and piping relieving devices that discharge directly to the
atmosphere with a maximum pressure less than 10 psig can be excluded from hydro
test.
• Instrument impulse lines shall be leak tested at least 30 minutes durations as
follows.
• The instruments impulse lines weather piping or tubing shall be pneumatically tested
with air or nitrogen at 1.1 times the design pressure.
• The test pressure shall be maintained for a sufficient time but not less than the 30
minutes.
• Underground process piping shall be tested prior to backfilling for minimum 2hrs
while the joints are inspected for leak.
• For FBE coated lines shall be tested as hoop stress cannot increase in the line to
prevent the internal coating.
• The test pressure the test pressure will be calculated based on nominal wall
thickness and flange ratings less than mill tolerate.
• The strength test shall be hold for minimum 2 hours. (Above Ground) L-150
• Strengthen + Tighten test shall be hold for minimum 24-hours. (Buried Pipe) L-150
29- Lay Up (after hydro test) SAES-A-007
Remove the hydro test water from the system. For facilities other than pipelines, drain the
system completely, sweep and mop as required to ensure that no visible traces of water
remain.
Wet lay up
Wet lay-up will require the use of water adequately treated with oxygen scavenger and biocide
at the beginning of the hydrotest and will require safety and environmental reviews of the
procedure.
For wet lay-up, establish and maintain throughout the system a minimum residual oxygen
scavenger concentration of 20 ppm in the water and a maximum oxygen concentration of 10
ppb. This includes dead legs. Analyze water sample(s) for residual levels of oxygen scavenger
and the dissolved oxygen concentration at the location most remote from the oxygen scavenger
inlet. Record the test results in the hydrostatic test report. Once minimum residuals are verified,
keep the system tightly closed to prevent air entry. Repeat tests and ensure chemical residuals
every six months during lay-up unless the physical location of the line or equipment makes this
impossible. If a leak occurs or air enters the system, lay-up the system again after completing
repairs.
Dry lay up
Dry lay-up may be achieved using several different drying media. These include hot dry air,
controlled dew point inert gas, and drying chemicals such as glycol or methanol applied between
two pipeline scrapers or as a gelled scraper. The best results may be achieved by using a
combination of these techniques.
Dry lay-up using hot or dew point controlled air may only be used for systems where the dew point
can be successfully reached within 1 week. Longer drying periods using air may contribute to the
generation of excessive quantities of corrosion products in lines. Therefore, dry lay-up using air is
only appropriate for systems that can be easily dried. One means to assure effective drying within
the required time is to limit the length of the system being hydrotested at one time.
Sweet gas may be used for dehydration. However, before using sweet gas ensure that hydrate
formation will not be a problem. Hydrate formation may occur at low temperatures and elevated
pressures.
Immediately after dewatering, start drying the system to a dew point that will ensure a dew point of
-1°C or less at the final lay-up pressure at all exit points. Dry by blowing sweet gas, nitrogen, or, if
pre-approved, heated dry air through the system for not less than 12 hours to allow any remaining
moisture to come to equilibrium with the dry air. Check and ensure that all measurement locations
are at or below the required dew point. Repeat the drying procedure if the measured dew point at
any one location is above the set limit.
For pipelines, dew point readings must be done at the beginning, end, and all mainline valve
locations.
Inert Gas lay up

Displace the hydrostatic test water by positive pressure with nitrogen or sweet gas until no water
drains out of the system. Shut in the system under positive pressure until commissioning and start-
up. Ensure that systems being drained have vacuum relief valves and pressure relief valves as
necessary to protect the system.
For pipelines, displace water by scraping with a three- or four-cup displacement scraper or
better system such as a gelled scraper.
Shut in the system at 2-10% of operating pressure but not exceeding 50 psig with
nitrogen or hydrocarbon gas.
Displace the hydrostatic test water with nitrogen or sweet gas until no water drains
out of the system.
Ambient lay up
Remove all water from the system. For facilities other than pipelines, drain the system
completely, sweep and mop as required to ensure that no visible traces of water remain. For
pipelines, dewatering shall be performed by scraping with a three- or four-cup displacement
scraper (or better) unless system limitations make this option impracticable.
After removal of all water, close the system to prevent the entry of sand or rainwater.
Install a vacuum breaker unless it is demonstrated that the system will not collapse under
vacuum.
30- “B” items from Pre-Test checklist are cleared after testing during re-instatement to
close & certify test Packages.
31- Re- instatement
“B” items from Pre-Test checklist are cleared after testing during re-instatement to
close & certify test Packages.
All temporary items (support, spools, tested blind, gasket, nut/bolts) to be replaced
with correct permanent items (control valve, supports, gasket, bolt, nuts, etc.,)
Verify the bolt torquing & tightening as per the specification (SAEP-351).
Verify all vent and drains are plugged and seal welded.
Proper lubrication applies the bolt, valve spindles.
All piping components are installed or re-installed in their respective locations as
shown in the P&ID ( i.e. : piping, removable pipe spools, valves, vents ,drains,
spectacle plates, blinds, flange spacers etc.
All nuts and bolts of flange connection are fully engaged.
All pipe supports are in full contact with the supports and carries the load.
Contractor will follow Saudi Aramco standard and SAIC-L-2028, SATR-A-2011
32- Client Walk Through (PMCC Punch List)

33- MCC
34- TIE-IN WORKS PROCEDURE
REFERENCES
SAES-L-350 Construction of Plant Piping

SAES-L-105 Piping Material Specification
SAES-L-460 Pipeline Crossing under Roads and Rail roads.
SAES-L-450 Construction of On-Land and Near-Shore Pipelines
SAES-H-200 Storage, Handling and Installation of Externally Coated pipe.
SAES-L-110 limitation on Piping Joints and Components.
SAES-W-011 Welding Requirement for On-Plot Piping.
SATIP-L-450-03 Cross Country Above Ground Pipeline
SATIP-L-450-04 Cross Country Buried Pipeline
SATIP-L-350-02 Piping Tie-In Installation
procedure
Tie-Ins
All tie-ins shall be done in accordance with SAES-L-450. Tie-in shall be carried out as per approved
procedure. QC Inspector shall maintain a permanent record of all actual tie-ins performed.
Minimum tie-in temp, shall be 70 -deg. F. or as given in the Safety Instruction Sheets (SIS).
A tie-in welds is a weld that connects the pipeline string to another or the pipeline under
construction or to an anchor. The segment of the pipeline between the tie-in points
remains fully restrained at the tie-in temp., if shrinkage of the segment is prevented by
adequate anchorage at both ends. For normal daily temp., variations during construction, one of
the following will provide adequate:
Full Thrust Anchor
Intermediate anchor with a full string of pipe welded to each side of the anchor; or
Frictional forces along the tail: at least 450 m. of buried pipeline; a 900 to 1200 or long
string on wooden skids or sand; or 1800 to 2400 of pipe, a double string resting on steel
supports.
The pipes to be tied-in shall be kept near to each other. During the peak temperature of the day,
the pipe shall be marked and cut. The bevel end shall be brought together and aligned using an
external clamp. The joint shall be welded using dolly mix procedure.
The pipe string shall not be lifted to take the slack in the string. The tie-in temperature shall be
equal to or greater than the highest mean temperature of the previous three days.
Notice of inspection shall be issued to Project Inspection 24 hours in advance for witnessing tie-
ins.
Tie-In to Existing Facilities

All tie-ins to existing facilities as indicated in construction drawings shall be verified with regards
to location, orientation and dimension prior to final fabrication.
DOCUMENTATION:
SAIC-W-2057 and SATR-W-2014
Cold Cutting:
Cold cutting technicians can simultaneously cut and bevel piping without the use of open flames or
producing sparks in facility. Cold cutting offers many advantages over other methods of pipe
cutting. Because there is no spark or flame produced, cold cutting does not require lines to be gas
free. In some instances this also eliminates the need to obtain a hot work permit to simply cut a
piece of pipe.
Mostly machinery applications and can perform many operations.
The application range of the pipe cold cutter is from 2 – 48 inch (76 mm - 1219 mm) O.D. and for
wall thickness up to 80 mm. The split construction type machines can be mounted on assembled
stretches of the work piece. Special equipment like remote control are available for limited access.
The pipe cutting machine is designed in a compact way with aluminium alloy components, which
give huge benefits to welder. The machine is very compact for limited access operations and
reduced in weight for more ergonomic work.
Saudi Aramco 5645-2-ENG (02/2002)
PMT OPRNS
SAUDI ARABIAN OIL COMPANY
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBTAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.
SAFETY INSTRUCTION SHEET FOR CROSS COUNTRY PIPELINE - CRITICAL PIPING
1 PIPELINE NAME 2 START POINT 3 END POINT 4 SERVICE 5 VALVE OPER. DIAGRAM 6 YR. BUILT
ENGG CERT
BLOWDOWN LINE WELLHEAD 2"-BD-0121-9ØSDØP KHUFF / JAUF GAS N.A. *

7 EQUIPMENT NAME 2"-BD-0112-9ØCS1T EQUIPMENT NAME
8 LOCATION (@ Km.) HWYH/HRDH LOCATION (@ Km.)
9 SECTION SECTION
10 EQUIP. CATEGORY WELLHEAD PIPING EQUIP. CATEGORY
11 SIZE (in.) 2 in. SIZE (in)
KILL LINE CALCULATION MOVED TO SHEET 003
12 W.T. (in.) 0.436 W.T. ( in)

13 MATERIAL C.S. MATERIAL
PIPE
PIPE
14 WELD TYPE SMLS WELD TYPE
15 SPEC. / GR. API-5L-X60 SPEC. / GR.
DESCRIPTION
16 COATING TYPE APCS-26 COATING TYPE

EQUIPMENT DATA
17 RATING API 3000# RATING

FITTING
FITTING
18 FACING RTJ / HUB FACING
19 MATERIAL C.S. MATERIAL
20 SPEC. / GR. API-6BX SPEC. / GR.
21 REMARKS REMARKS
DATE JO/EWO
10-00225-
0425
22 M.A.O.P. 3000 PSIG, LIMITED BY: API 3000# FLG. M.A.O.P. PSIG, LIMITED BY:
03/2011
23 DESIGN FACTOR 0.50 DESIGN FACTOR

o
24 DESIGN TEMPERATURE: 300 F DESIGN TEMPERATURE (oF) o
F
25 TEST PRESSURE 6000 PSIG INITIAL TEST PRESSURE PSIG
REV.
INITIAL
0F1
NO.
PRESSURE 26 TEST DATE * PRESSURE TEST DATE

OPERATING LIMITS
DISCIPLINE TEST 27 LIMITED BY API 3000# FLG. TEST LIMITED BY

ENGINEER
MB 28 TEST PRESSURE * PSIG TEST PRESSURE PSIG
DATE: 03/2011 REVALIDATION 29 TEST DATE * REVALIDATION TEST DATE
PROJECT 30 LIMITED BY * LIMITED BY
ENGINEER
AAS 31 SYSTEM M.A.O.P. 3000 PSIG SYSTEM M.A.O.P. PSIG
DATE: 03/2011 32 LIMITED BY API 3000# FLG. LIMITED BY
CERTIFIED 33 SAFETY VALVE SET PRESS. **6300 PSIG PZV SAFETY VALVE SET PRESS. PZV
AAS DES THK @ 34 PIPE SIZE 2 in. in. in. DES THK @ PIPE SIZE in. in. in.
DATE: 03/2011 SYSTEM MAOP 35 PIPE Tm 0.123 in. in. in. SYSTEM MAOP PIPE Tm in. in. in.
CONSTRUCTION & DES TEMP 36 PIPE Tca 0.313 in. in. in. & DES TEMP PIPE Tca in. in. in.
AGENCY
ASA 37 OSI DATA POINTS OSI DATA POINTS
OSI DATA POINT INFO.
DATE: 03/2011
OPERATIONS SEQ. DATE WT (in) DATE WT (in) DATE WT (in) SEQ. DATE WT (in) DATE WT (in) DATE WT (in)
1 1
DATE: 2 2
3 3
CONTROL NUMBER
VERIFICATION
4 4
EDSD
5 5
6 6
38 REMARKS
DATE:
REMARKS
BY:
* TO BE FILLED OUT BY CONSTRUCTION CONTRACTOR DURING THE TEST.
** SAFETY VALVE SET PRESSURE SHALL BE FOR STRENGTH TEST ONLY.

REVISION CERTIFICATION
APPROVAL/CERTIFICATION REQUIREMENTS.
0F1
OF THIS DRAWING IS COVERED, FOR ALL
BY DRAWING COMPLETION CERTIFICATE
39 REFERENCE DWGS REFERENCE DWGS

10-00225-0425-001
ANSI B31.8/API-6A.
THIS INDICATES THAT REV. NO.
P & ID BA-xxxxxx
HYD. TEST DIAG. BA-735963
SIS FOR SAFETY INSTRUCTION SHEET DWG. TYPE PLANT NO. INDEX DRAWING NO. SHT.NO. REV.NO.
JAUF/UNYZ CROSS COUNTRY PIPELINE - CRITICAL PIPING SIS
(DCC) NO.:
A BE- 735968
2'-BD-0112-90CS1T, 900# MODEL, REV. 6 004 0F1
HWYH/HRDH SAUDI ARABIA JO / EWO 10-00225-0425
EDSD/5645-2-0202.XLS
Saudi Aramco 2821 ENG (12/2001)
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN ARE THE SOLE PROPERTY OF SAUDI ARAMCO. NO REPRODUCTION IN FULL OR IN PART SHALL BE OBATAINED FROM THIS DOCUMENT WITHOUT THE WRITTEN CONSENT OF ITS OWNER.
PMT OPRNS
SAUDI ARABIAN OIL COMPANY

SAFETY INSTRUCTION SHEET - CRITICAL PLANT PIPING
1 LINE NUMBER 2"-BD-0110/0111-95CS1T
CERT
2 START GAS WELLHEAD

END BLOWDOWN
ENGG
3
4 SERVICE ANNULI RISER PIPING
PIPE W. T. CALCULATED RECORDING TO ASME B31.3 PER SAES-L-105
5 PIPING CODE/ YEAR ASME B31.3, CHAPTER IX YEAR 2008

6 P&ID's OR BA-735963.001, REV-6, GAS WELL MODEL DRAWING
LINE DESIGNATION TABLE
7 NOMINAL PIPE SIZE 2 in. in. in. in.
DESCRIPTION
8 PIPE O.D. 2.375 in. in. in. in.

9 NOM. WALL THK. 0.436 in. in. in. in.
10 MATERIAL SPEC. API-5L; PSL-2
PIPE
11 MATERIAL GR. X60

12 ALLOWABLE STRESS 25,000 PSI PSI PSI PSI
13 WELDED/ SMLS SMLS
14 WELD JOINT EFFICIENCY 1.00
15 RATING API - 10000
FLANGES
JO/EWO
10-00225-
16 FACING RJ
EQUIPMENT DATA
0425
17 MATERIAL SPEC. AISI 4130

03/2011
18 MATERIAL GR. 75K

DATE
FITTINGS
19 RATING XXS
20 MATERIAL SPEC. ASTM A860
NO.
REV
0F1
21 MATERIAL GR. WPHY-60

DISCIPLINE 22 REMARKS :
ENGINEER
MB D - 2C 2.375
t= 1 - exp (- P/S) = 1 - exp (- 7500 / 25000) = 0.3077
DATE: 03/2011 2 2
PROJECT WHERE:
ENGINEER
AAS D = OUTSIDE PIPE DIAMETER (INCHE)
DATE: 03/2011 C = EXTERNAL CORROSION ALLOWANCE = 0
CERTIFIED P = DESIGN PRESSURE (PSI)
AAS S = ALLOWABLE STRESS FROM TABLE A-1, ASME B31.3 (PSI) AT DESIGN TEMPERATURE
DATE: 03/2011 23 DESIGN PRESSURE 7,500 PSIG KPa
CONSTRUCTION 24 DESIGN TEMPERATURE 300 °F °C
AGENCY
ASA 25 LIMITED BY DESIGN CONDITION
DATE: 03/2011 26 TEST PRESSURE NEW 11250 PSIG KPa
OPERATIONS 27 LIMITED BY 1.5X DESIGN PRESSURE
28 SAFETY VALVE SET PRESSURE 11812 PSIG KPa
DATE: 29 tm (Pressure) 0.3077 in. in. in. in.
OPERATING LIMITS
30 Req. Corr. Allow. (1) 0.063 in. in. in. in.

CONTROL NUMBER
VERIFICATION
31 tm (Code) (2) 0.4147 in. in. in. in.

EDSD
32 tm (Structural)
(CONTACT OPERATIONS ENGINEERING BEFORE EXCEEDING THE ABOVE LIMITS)
DATE:
33 REMARKS:
BY:
(1) CORROSION ALLOWANCE 1.6MM PER SAES-L-105 FOR LINE CLASS 95CS1T.
(2) REQUIRED MINIMUM NOMINAL PIPE WALL THICKNESS WITH 12.5% TOLERANCE AND CORROSION ALLOWANCE.
REVISION CERTIFICATION
APPROVAL/CERTIFICATION REQUIREMENTS.
OF THIS DRAWING IS COVERED, FOR ALL
BY DRAWING COMPLETION CERTIFICATE

0F1
10-00225-0425-001
THIS INDICATES THAT REV. NO.
SIS FOR DWG TYPE PLANT NO. INDEX DRAWING NO. SHT. NO. REV. NO.
GAS WELLHEAD - CRITICAL PIPING

SIS A BE- 735968
(DCC) NO.:
2"-BD-0110/0111-95CS1T, 900# MODEL, REV. 6 003 0F1

HWYH/HRDH SAUDI ARABIA JO / EWO 10-00225-0425
EDSD/2821-1201.XLS

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QC Piping Inspector – Hand Book

With ARAMCO Engineering

1- Project Scope of Work

2- Code, Standard & Procedure

SECTION-1 Rules for Construction of Power Boilers

ASME 31.1 (Pressure Piping, Power Piping)

ASME B16.1 Cast iron pipes flanges & flanged fittings

4- Materials (Pipe, Fittings etc) –Piping Design

Concentric reducer is used in pump suction. (Yes / No). Explain. Answer:

4. Olets OLET use for connecting Main Line to Branch Line

5. Valve Types of Valves

1-Check Valve (Non Return Valve)

Valves are classified based on its method of operation as: -

Valves are classified based on end connection as: -

Pipe Flanges and types.

1. Weld Neck Flange

Flange Facing Types

Application forSocket weld flange

1- Weld Neck Flange

A weld neck flange is a type of steel flange designed to transfer

A Socket Weld Flange is similar to slip-on flanges, however, socket welds

Code Of Pipe & Fittings

Grade & Specification of

Lateral / Reducer = Fittings Grade & Specification

1. Isometric drawing. IFC – Issued for Construction.

Abbreviations use in P& Id

1. CB (Chilled Carbon Steel).

Level-0 Documentation requirement only; no vendor inspection required.

SAMSS (Saudi Aramco Materials System Specifications)

Seamless Pipe or Welded Pipe: (Straight/ Spiral)- SAW

Valve: (04-SAMSS-035 General Requirements)

Ocular inspection on the material or equipment is conducted by the Material Controller to

Verification of Associated Documents (SAIC-L-2005) – SATIP-L-350-01 & 08

Purchase order Information

√ The applicable code (ASME B31.1,B31.3,B31.4 or B31.8 )

Transportation and Handling

Equipment and experienced personnel shall be provided to handle products by methods to

Notice to Inspection (NTI)- Internal RFI

NCR shell be issued in accordance with QAP-11, Rev. 00.

Request for Inspection (RFI)

Material Specification, Grade, Etc.

Materials storage shall be in an easily identifiable manner.

9- Material Handling, Preservation and Storage

Storage for Bulk Materials:

Storage of ESD Material

• Materials which are damaged during transportation

Items found damaged or unsuitable during installation, shall be:

Replaced, unless modifications, or repair, can be satisfactorily demonstrated to Saudi Aramco

Material Issuance and Inventory

Type of material use accordingly to temperature?

Ensure that all material (spool) free from damages.

14- PWHT (welding inspector scope)

16- Spool Release Inspection for Painting - IRC

17- Coating & painting (painting inspector scope) (SAES – H- 1002)

Coating & painting to be done (if required).

18 - Spool Release Inspection for Site - IRC

22- Welding /NDT/ PWHT

23- Valve Installation

Installation of Flanged Joints

Bolt tightening procedure and sequence refer to SAEP-351.

SAES-L-350 Construction of Plant Piping