American Society of Mechanical Engineers (ASME)

ASME B31.1 - Power Piping

ASME B31.3 - Process Piping
ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
ASME B31.5 - Refrigeration Piping
ASME B31.8 - Gas Transmission and Distribution Piping
ASME B31.9 - Building services piping
ASME B31.11 – slurry Transportation System
ASME B31.12 – Hydrogen Piping and Pipeline
ASME SEC I – Rules for Construction of Power Boiler
ASME SEC II – Materials
a) Ferrous Materials Specifications.
b) Non Ferrous Materials Specifications.
c) Specifications of electrodes and filler wires
d) Properties
ASME SEC IV – Rules for Construction of Heating Boiler
ASME SEC V – (NDE) Non Destructive Examination
ASME SEC VIII – Rules for Construction of Pressure Vessels
ASME SEC IX – Welding and Brazing Qualifications
ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings
ASME B16.5 – Carbon Steel Pipe Flanges and Flanged Fittings up
to 24”
ASME B16.9 - Steel Butt welding Fittings
ASME B16.10- Face to face & end to end dimension f valve
ASME B16.11 -Forged Steel Socket-Welding and Threaded Fittings
ASME B16.20 - Metallic Gaskets for Pipe Flanges
ASME B16.21 - Nonmetallic Gaskets for Pipe Flanges
ASME B16.25 – Butt welding Ends
ASME B16.28 - Steel Butt welded Short Radius Elbows and Returns Bends
ASME B16.34 - Valves (Flanged, Threaded and Welding End)
ASME B16.36 - Orifice Flanges
ASME B16.39- Malleable Iron Threaded Pipe Unions
ASME B16.47- Large Diameter Flanges (Above 24’’)
ASME B16.48- Spectacle plate, Blank & Spacer
ASME B36.10 - Welded and Seamless wrought iron pipes
ASME B36.19 – Stainless Steel pipes

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American Petroleum Institute (API)
API SPEC 5L- Specification for Line Pipe

API SPEC 6D - Specification for Pipeline Valves

API STD 599- Metal Plug Valves-Flanged, Threaded and Welding Ends

API STD 600- Steel Gate Valves-Flanged and Butt-Welding Ends

API STD 602 -Steel Gate, Globe, and Check Valves for Sizes NPS 4 and Smaller for the Petroleum and
Natural Gas Industries

API STD 607 -Fire Test for Quarter-Turn Valves and Valves Equipped with Nonmetallic Seats

API RP 941- Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries
and Petrochemical Plants

API-570 – Piping Inspection Code

API-598 – Valve Inspection and Testing

API-601 – Metallic Gasket

API 609 - Butterfly Valves, Lug-Type and Wafer-Type

SATIP
SATIP-A-004-01 – Pneumatic Testing

SATIP-A-004-02 – Hydro Testing of On plot

piping SATIP-A-004-03 – Hydro Testing of

Pipelines SATIP-A-004-05 – Leak Testing

SATIP-L-108-01 – Valve Inspection , Testing and

Installation SATIP-L-350-01-- On-Plot Metallic Piping

Installation

SATIP-L-350-02-- Piping Tie-In Installation For Plant Piping

SATIP-L-350-05-- Fire Water Distribution Piping

Installation

SATIP-L-350-06 - PLANT PIPING - Steam & Steam Condensate

Piping SATIP-L-350-07 - Cement Lined Pipe Installation

SATIP-L-350-08 - Shop Fabrication - Piping & Miscellaneous Steel Structures

2
SATIP-L-350-09- Utility Piping Installation - Plant Air & Nitrogen

Gas SATIP-W-011-01- Welding of On-Plot Piping

SATIP-J-600-01 - Safety Relief Valve Installation

SAES
SAES-L-100 - Applicable Codes and Standards for Pressure Piping

SAES-L-101- Regulated Vendor List for Pipes, Fittings and Gaskets

SAES-L-102 - Regulated Vendor List for Valves

SAES-L-105 - Material Specifications for Piping

Systems SAES-L-108 - Selection of Valves

SAES-L-109 - Selection of Pipe Flanges, Stud Bolts and

Gaskets SAES-L-110- Limitations on Piping Joints and

Components SAES-L-120- Piping Flexibility Analysis

SAES-L-125- Safety Instruction Sheet for Piping and Pipelines

SAES-L-130 - Material for Low Temperature Service

SAES-L-131- Fracture Control of Line Pipe

SAES-L-132- Material Selection for Piping Systems

SAES-L-133 - Corrosion Protection Requirements for

Pipelines/Piping SAES-L-136- Pipe Selection and Restriction

SAES-L-140 - Thermal Expansion Relief in Piping

SAES-L-150 - Pressure Testing of Piping

Systems SAES-L-310 - Design of Plant Piping

SAES-L-350 - Construction of Plant Piping Systems

SAES-A-004 – General Requirements of Pressure Testing

SAES-A-007 – Hydrostatic Fluids and Lay-up Procedures

SAES-B-017- Fire Water System Design

SAES-L-410 - Design of

Pipelines SAES-L-610 -

Nonmetallic Piping
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SAES-S-020- Oily Water Drainage System

SAES-W-011- Welding Requirements for On-Plot Piping

SAES-W-012 - Welding Requirements for Pipeline

SAES-A-206 - Positive Material Identification

SAES-H-002- Internal and External Coatings for Steel Pipelines and Piping

SAES-J-100 – Process flow metering

SAEP
SAEP-302- Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering

Requirement SAEP-1150 - Inspection Coverage on Projects

SAEP-1151 - Inspection Requirements for Contractor Procured Materials and Equipment

SAEP-1154 - Guidelines for Contractor's Quality Plan

SAEP-1160 - Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects

SAEP-327 - Disposal of Wastewater from Cleaning, Flushing and Dewatering Pipelines and

Vessels SAEP-351 - Bolted Flange Joints Assembly

SAIC & SATR

● Pre-Welding & Weld Joint Fit-Up Inspection – SAIC-W-2005 & SATR-W-2006
● Branch connections
a) Integrally reinforced welding
outlets, i.e.: Weld-o-lets, weld
boss
c) Reinforced stub-ins
● Threaded connections inspection - SAIC-L-2015
● Venturi, Flow Orifice Plate & Restriction orifice installation - SAIC-L-2016
● Thermowell Installation - SAIC-L-2020
● Chemical Injection & Sample Connections - SAIC-L-2021
● Relief valve installation - SAIC-J-2009
● Bolt Torquing – SAIC-L-2014 & SATR-L-2001
● Valve Installation – SAIC-L-2043
● Pre-Test Punch List – SAIC-A-2010 & SATR-A-2007
● Internal Cleaning – SAIC-L-2017 & SATR-A-2008
● Pressure Gauge Calibration Report – SATR-A-2002
● Relief Valve Calibration Report – SATR-A-2006
● Water Analysis Report – SATR-A-2014

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Hydro Test Checklist & Report

● Verification of Testing Equipment – SAIC-A-2009

● Inspection of Pressure Test Preparation - SAIC-A-2011
● Inspection of Filling and Pressurization - SAIC-A-2013
● Visual Inspection at Pressure Test - SAIC-A-2015
● Depressurization and Disposal of Waste Water - SAIC-A-2017
● Pressure Test Report – SATR-A-2001

● Lay-up Inspection – SAIC-A-2018 & SATR-A-2009

● Reinstatement – SAIC-L-2022 & SATR-A-2011

Pneumatic Test

Pressurization of Pneumatic Test (Strength & Service) - SAIC-A-2020

Inspection of Pneumatic Test (Strength & Service) - SAIC-A-2021

Depressurization of Pneumatic Test (Perform Leak Test) - SAIC-A-2022

Pressurization for Bubble Leak Test (Using Air, Inert Gas) - SAIC-A-2023

Inspection of Leaks for Tightness Testing - SAIC-A-2024

Duties & Responsibilities

To Control all the Quality Related activities as per approved standard and procedures

□ Material Receiving
□ Fabrication and Erection as per standards
□ Valve installation and Bolt torquing flange joint assembly
□ Pre-Test punch listing
□ Internal Cleaning
□ Testing (Hydro, Pneumatic, Service)
□ Lay-up
□ Re-instatement

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Schedule Q

It is the minimum Quality Requirement for Contractor and Sub contractor quality System.

Quality Plan

It is a document, that specify quality standards, specifications and the sequence of activities to a
particular project or contract.

SATIP

Saudi Aramco Typical Inspection Plan. It Includes Sequence of various activities perform and inspections
and these sequence of activities are (1) Documentation Review (2) Material Receiving (3) Installation
(4) Pre-Commissioning

Pre-Commissioning

To check the ability to withstand the operating pressure prior to the introduction of final product

Inspection Action Points

□ Hold :- QA/QC organization shall be notified of the timing of inspection or test in advance.
Inspection or test shall not be carried out without the QA/QC organization representative in
attendance.
□ Witness :- QA/QC organization shall be notified of the timing of Inspection or test in advance.
However, the inspection or test shall be performed as scheduled if the QA/QC organization
representative is not present
□ Review :- Activity can proceed with approved Documents
□ Surveillance :- QA/QC organization to monitor work in progress without notice
from Construction Organization.

Material Receiving
o Purchase Order
o Delivery Note
o MTC
o MTO
o Inspection Release Certificates (IRC)
o Vendor Approval

Material Identification
All pipe and fittings shall have the material specification and grade stamped, stenciled, or otherwise
clearly marked with permanent marking method

9COM : - Commodity Classification Code number used in the SAP system to procure material

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 CCC :- “Commodity Classification Code”

❖ Minimum Inspection Levels of Material Receiving

o Level 0 :- Documentation requirements only; no vendor inspection required.

o Level 1 :- Only final inspection is required prior to shipping.
o Level 2 :- Includes pre-inspection meetings, one or more unspecified “in progress”
surveillance visit/s, all witness and hold points, final inspection, and release for shipment.
o Level 3 :- Includes pre-inspection meetings, one or more unspecified “in progress” surveillance
visits, all witness and hold points, final inspection, and release for shipment. Inspections shall be
on a regular basis (daily, weekly or bi-weekly).
o Level 4 :- Resident inspector continually monitoring the work

o PRESERVATION (Storage and Handling)

o Pipe shall not be stored directly on the ground. Pipe shall be placed on mounds or sleepers
o Stacking of pipes shall be made in a manner to avoid damage to pipes or coatings.
o Fittings and valves shall be stored in shipping crates or on racks
o End protectors on pipes, flanges, weld bevels, threads, and socket ends shall be
firmly attached
o Stainless steel material shall be protected against exposure to seawater splash
during shipment and storage
o Lined and coated pipes and fittings shall be lifted with wide fabric or rubber covered slings
and padding shall be used to prevent damage to lining or coating
o All materials shall be handled with care during fabrication and installation to
prevent damage
o Pipe Fit-Up and Tolerances
o The maximum tolerance for axial dimensions, face-to-face, center-to-face and location
of attachments shall be ± 3 mm.
o Flattening of bends, measured as the difference between the largest and the smallest outside
diameter at any cross section, shall not exceed 5% of the nominal diameter of the pipe.
Flattening of bends at weld ends shall not exceed 3% of the nominal pipe diameter.
o Lateral transition of branches and connections from the centerline of the run shall not exceed
± 1.5 mm.

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 o 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.
o The tilt of a flange measured at the periphery across any diameter shall not exceed 1.6
mm from the square position.
o For piping over 3-inch NPS and connected to machinery/equipment, flange alignment shall
be within the following
a) Vertical bolt hole offset : ± 2.4 mm
b) Horizontal bolt hole offset : ± 2.4 mm
c) Rotational offset : ± 2.4 mm
d) Flange face tilt across diameter: 0.025 mm per 25 mm (0.001 inch per inch) of flange outside
diameter up to a maximum of 0.672 mm (0.030 inch), and 0.254mm (0.010 inch) for all flanges
with an outside diameter less than 10 inches.
e) Flange face separation, gasket thickness : ± 1.6 mm
f) Combination of vertical, horizontal and rotational offset : ± 3.2 mm
o In the case where a spectacle plate is installed between two flanges, these tolerances can
be increased by 30% except for tolerances for flange face tilt across diameter and flange face
separation.
o Internal misalignment (High-Low) of butt joints shall not exceed 1.5 mm.
o If post-weld heat treatment (PWHT) of pipe spools is required , non-pressure containing
welded attachments such as shoe support for insulated lines, dummy extensions and legs, and
wear pads shall be welded to the pipe spools before stress relieving. PWHT of piping spools
with flanged joints shall be done before flange assembly

Dummy Supports
o A 6 mm weep hole shall be drilled for all dummy supports. The weep hole shall be located near
the base plate for all vertical dummy supports, and near the run pipe at 6 o'clock position for
all horizontal dummy supports.
Low Friction Support
o Teflon sheets or similar low friction materials are used to function as low friction
supports Sliding surfaces shall be protected from paint and sand blasting.
o Provision shall be made to allow angular adjustment of the bearing surface during
installation, so that an even distribution of the load can be assured.

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 o Low friction supports shall be constructed such that sand or other debris cannot accumulate
on sliding surfaces (by making the top surface larger than the bottom surface).

Spring Supports
o The spring setting shall be verified that they are matching the design requirements.
o The spring support shall be in full engagement with pipe.
o All springs shall be in compression, so that failure will not result in the complete release of load.
Springs shall be factory set to the calculated cold settings by means of travel stops. Upper stops for
load preset and lower stops for hydro-test shall be provided. These stops shall be banded or
locked in place so they cannot be easily dislodged during erection or hydro-test. The travel
stops shall be painted red and shall have a bright color tag indicating “Remove after Hydro-
test.”
o Each spring hanger assembly must be capable of sustaining the load during hydro testing,
which is equal to 2 times the operating load.
Hanger Rods
o Rod hangers shall not be used for lines 12” NPS and larger in liquid service or multi-phase flow.
o All hangers shall be provided with means for vertical adjustment
o Suitable locking devices shall be used at all threaded connections of the hanger
assembly (double nuts).

o Bolt Torquing Procedure

o Bolts, nuts and washers shall be visually checked for proper size, grade, and dimension and
for any physical damage Also, the suitability of the stud bolts and nuts material for the service
temperature and the compatibility with the flange material shall be checked.
o The bolts/nuts combinations for which the nuts will not turn freely by hand shall be verified
o The gasket rating and dimension for piping system shall be verified as required by ASME
B16.20 and ASME B16.21.
o The gasket seating Area shall be examined for compliance with the recommended surface
finish and for damage to surface finish such as scratches, nicks, gouges and burrs
o The nuts shall be turned freely by hand before applying the lubricant
o Lubricant shall be applied to both the nut bearing surface and the male threads.
o Align the Flange and Gasket
o Torque wrench should be calibrated. accuracy should not exceed ±5%.
o Torquing crew shall be proper trained people
o Mark the studs as per tightening Sequence
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 o Tightening shall have a minimum of four passes (33%-66%-100%-100%) to achieve the
required torque load
o The nuts shall have full thread engagement after the flange assembly.

Note:- Torque values shall be determined according to flange rating, bolt size, type of gasket, and the
lubricant’s friction factor

□ Spiral Wound gasket:

Outer rings are required for all pipe sizes.

Inner rings are required for the following flanges:

1. Flanges size 24” and larger;

2. Flange class 900# and above;

3. Spiral wound gaskets with graphite or PTFE filler materials.

4. Flanges in vacuum services.

□ When raised face flanges are to be used, the flange finish shall be 3.2 to 6.4 micrometers Ra
□ For hydrogen service, flange facing surface finish for raised face shall not exceed Ra
3.2 micrometers (125 microinch).
□ For general hydrocarbons and process hydrocarbon services including steam, ASME B16.20
spiral wound gaskets with 316 stainless steel winding and high purity flexible graphite filler
shall
be used for raised face flanges
□ Spiral wound gaskets with graphite filler material is limited to 425°C
o Ring joint Gasket
□ The dimension of the ring-joint gasket indicated by letter designation (R, RX, or BX) stamped on
the ring gasket was verified to conform with the flange size and flange standard where it will be
used.
□ Rubber coated ring joint gaskets may be used for severely corroded services. Soft iron or low
carbon steel may be used for the ring type joint material.

o Ring joint flanges for use with ring joint gaskets per ASME B16.20 shall be used for:
□ Flanges in Class 900 and higher ratings

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 □ Underwater pipelines in Class 300 and higher ratings,
□ Design temperatures in excess of 480°C,
□ API SPEC 6A Type 6B flanges,
□ Hydrogen service in Class 300 and higher ratings.
o Material Selection for Bolts and Nuts
□ Process and general services :- (- 40 to 450) - A193 Grade B7 & A194 Grade 2H
□ Low temperature services :- (- 73 to 450 ) - A320 Grade L7M & A194 Grade 7M

(-101 to 343) - A320 Grade L7 & A194 Grade 4 or 7

□ High temperature services :- ( 450 to 645)- ASTM A193 Grade B16 & A194 Grade 4
□ Wet sour services :- (-48 to 450) - A193 Grade B7M & A194 Grade 2HM

(- 73 to 450) - A320 Grade L7M & A194 Grade 7M

● PIKOTEK Gaskets
Pikotek Gaskets are used to dissimilar metal flanged joints with high potential galvanic corrosion and
Insulting joints for cathodic protection.
PIKOTEK gaskets shall not be used in services operating at 280°F and higher.

● Parts of Pikotek Gasket

Insulation Gasket
Insulating sleeve
Insulating washer
Plate washer

□ Pikotek Gasket for water corrosive services where flange face corrosion is a concern,
Gaskets with Teflon sealed, glass reinforced epoxy laminated to 316 stainless steel core.

● Flange Standards
□ 24 inch size and smaller flanges shall be as per ASME B16.5.
□ Above 24 size inch flanges shall be as per ASME B16.47 series A.
□ ASME B16.47 Series A flanges are identical to MSS SP-44 flanges.
□ API SPEC 6A , 6B Flanges shall be rating 3000 and above, from 1½-inch to 10-inch NPS
● Blind Flanges
A105N, from - 20°C to 425°C

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A350 LF2 Cl 1, from - 45°C to 425°C
A516 Gr 70 N, from - 45°C to 425°C.

● Maximum Size for the Allowed Bore in the Blind Flanges

Size of NPS Flanges Maximum NPS for Tapped
Pipe 4” 1½”
6” 2”
8”-14“ 3”
16” and larger 4”

● Types of Flanges
□ Weld neck flanges
□ Slip on flanges
□ Lap joint flanges
□ Socket welded flanges
□ Screwed flanges
□ Threaded flanges
□ Orifice flanges
□ Blind flanges
□ Integral flanges
□ Swivel ring flanges
□ Weld neck flanges –used for but welding where Radiography is required.it is commonly used
for 2” and above and also used for high pressure services.
□ Slip on flanges – it is a double welded joint flange. one joint with hub and other joint with
bore Slip-on flanges are used only for category D services.
□ Lap joint flanges – it is used to avoid welding dissimilar metals where the pipe stub-end is
made from high alloy material and the flange body is made from carbon steel.it is also used for
Easy
alignment of bolt holes.
□ Swivel ring flanges - swivel ring flanges used for underwater pipe tie in connection
□ Threaded flanges – used for threaded connection
□ Blind flanges – used for where flange to be re-open
□ Orifice flanges – used for process flow metering
□ Socket welded flanges - used for socket welding

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 ● Jackscrews shall be used to facilitate flange separation for maintenance
● For orifice flanges, jackscrews shall be installed at 3 and 9 o'clock positions.

o Bolt Tensioning Procedure ( HYDRATIGHT - 50% Tensioning Method)

o Bolts, nuts and washers shall be visually checked for proper size, grade, and dimension and
for any physical damage Also, the suitability of the stud bolts and nuts material for the service
temperature and the compatibility with the flange material shall be checked.
o The bolts/nuts combinations for which the nuts will not turn freely by hand shall be verified
o The gasket rating and dimension for piping system shall be verified as required by ASME
B16.20 and ASME B16.21.
o The gasket seating Area shall be examined for compliance with the recommended surface
finish and for damage to surface finish such as scratches, nicks, gouges and burrs
o The nuts shall be turned freely by hand before applying the lubricant
o Lubricant shall be applied to both the nut bearing surface and the male threads.
o Align the Flange and Gasket
o Mark the studs as per tightening Sequence
o Mark bolts in 2 Sets, Set 'A' & Set 'B', alternatively.
o Tensioners are fitted to every other bolt of Set 'A'.
o Pressurize the tensioners to pre-determined "Pressure A" per the approved procedure. (This
is repeated 2 more times.)
o Transfer tensioners to Set 'B' bolts and pressurize to pre-determined "Pressure B" and tighten
nuts. This is repeated 2 more times. (NOTE: Pressure B is lower in value than Pressure 'A')
o After tensioning, Break Loose Pressure (BLP) is verified to be greater than or equal to Pressure
B by the following steps:
o a) Fit tensioner to one of the tensioned bolts in Set 'A'.
b) Pressurize slowly until the nut is loosened using a Tommy Bar and socket.
c) Once the nut moves, stop pressurizing and record the achieved pressure. This is the
Break Loose Pressure(NOTE: If BLP < Pressure B, Tensioning is a Fail. )

❖ Bolt Tensioning Procedure ( HYDRATIGHT - 100% Tensioning Method)

o Bolts, nuts and washers shall be visually checked for proper size, grade, and dimension and
for any physical damage Also, the suitability of the stud bolts and nuts material for the service
temperature and the compatibility with the flange material shall be checked.
o The bolts/nuts combinations for which the nuts will not turn freely by hand shall be verified

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 o The gasket rating and dimension for piping system shall be verified as required by ASME
B16.20 and ASME B16.21.
o The gasket seating Area shall be examined for compliance with the recommended surface
finish and for damage to surface finish such as scratches, nicks, gouges and burrs
o The nuts shall be turned freely by hand before applying the lubricant
o Lubricant shall be applied to both the nut bearing surface and the male threads.
o Align the Flange and Gasket
o Mark the studs as per tightening Sequence
o Mark bolts in 2 Sets, Set 'A' & Set 'B', alternatively
o Tensioners are fitted to ALL bolts.
o Pressurize the tensioners to pre-determined "Pressure A" per the approved procedure. (This
is repeated 2 more times.)
o After tensioning, Break Loose Pressure (BLP) is verified to be greater than or equal to Pressure
A by the following steps:
a) Fit tensioner to one of the tensioned bolts in Set 'A'.
b) Pressurize slowly until the nut is loosened using a Tommy Bar and socket.
c) Once the nut moves, stop pressurizing and record the achieved
pressure. This is the Break Loose Pressure.
(NOTE: If BLP < Pressure A, Tensioning is a Fail. )

Notes - Manual torque wrenches shall not be used for 1” bolts size and larger.

SAES-L-109 – SELECTION OF VALVES

o all new valves designated for isolation service (as specified by the Proponent) shall be
subjected to a high pressure hydrostatic seat test prior to installation in the line. A
low pressure pneumatic seat test at (5 psig) shall be substituted for the high pressure
hydrostatic seat test for flare system valves

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 o Butt weld and socket weld end valves in nominal pipe size (NPS) 2 inches and smaller
are Exempted from field testing requirements for flare system valves
o All resilient (soft) seated isolation valves shall have zero leakage.
o Trim material :- includes the stem, the body and closure, seating surfaces, bushings,
pins, springs, guides, and any other small parts in contact with the service fluid
o The use of welded bonnet valves in hydrocarbon services shall be limited to NPS 4 inch
and smaller
o Screwed bonnet and screwed body valves shall not be used in any hydrocarbon or
hazardous material services unless the bonnets and body end connections are tack
welded to the body or provided with locking pin
o Union bonnet valves shall not be used in any hydrocarbon or hazardous material services
o In hydrocarbon services, the minimum body rating of threaded and socket weld end NPS
2 inch and smaller valves shall be equivalent to API STD 602 Class 800
o Chain wheel operation shall not be provided for emergency isolation valves or valves
having a threaded body connection.
o Gate valves with back-seats shall not be installed with their stems below the horizontal
except in the following cases: (a) clean services, (b) when they function as isolation valves
in pressure relief and flare system piping, and (c) when in utility or other similar non-critical
services (firewater is considered to be critical service).
o All threaded connections on valve bodies and associated piping shall be seal welded.
o Lever operated ball valves shall be equipped with a hand wheel or self-locking handle
to prevent accidental operation
o Concentric butterfly valves, such as the API STD 609 Category A type (typically with internal
rubber linings), are permitted only in non hydro carbon applications

❖ Butterfly valve Minimum requirements in hydrocarbon service are

□ Butterfly valves in hydrocarbon service shall be limited to a maximum rating of Class 900
□ Design according to API STD 609 Category B valves with offset-seat type construction.
□ Valve body shall be of the lug-type with tapped bolt holes or (double) flanged type has
been specified. (Use of the wafer-type body is not permitted)

15
□ Valves shall be full-rated. In systems where the normal operating pressure is 103 kPa (15 psig)
or less, the valve may be specified with half-rated trim (approximately 50% of the full-rated
pressure).
□ Valves shall be bi-directional, although they may have a "preferred" direction. Valves shall be
installed in the "preferred" direction indicated on the valve

Check Valves
□ Dual and single plate wafer check and swing check valves shall not be used in
reciprocating pump and compressor suction and discharge services or similar pulsating
services.
□ A non-slam internal-spring-assisted type check valve shall be installed at the discharge of
pumps and compressors.
□ For all sizes NPS 4 inch and above, a turbulence-free minimum distance of 5 pipe diameters
upstream and 2 pipe diameters downstream of every check valve shall be maintained. pipe
fittings such as elbows, reducers, tees, etc., or flow restricting devices such as orifices, control
valves, etc., shall not be installed in these zones

□ Check valves in sizes NPS 3 inch and above shall not be installed in vertical lines,
□ Check valves in hydrocarbon service up to Class 600 shall either have a lug-type body
with tapped bolt holes or a flanged body. In higher ratings, a flanged body is mandatory.
□ Wafer-type bodies are not permitted in any hydrocarbon service
□ Spring-assisted non-slam piston check valves (also referred to as nozzle check valves) shall
be long-pattern with face-to-face dimensions in accordance with API SPEC 6D
❖ Plug Valves
□ Used only for Hydrocarbon service
□ Flanged plug valves in hydrocarbon service shall be of the inverted lubricated pressure
balanced design, except that Class 150 valves NPS 6 inch and smaller may have a standard plug
with
springs for balancing the plug

❖ Note;- All valves in services below -45°C shall be full austenitic stainless
steel All valves in service below -100°C shall have an extended bonnet.
□ For LPG or high pressure gases which auto refrigerate, an upstream gate valve shall be
installed in addition to the throttling valve in any line that discharges to the atmosphere or to a
low
pressure system.

16
□ Under water Isolation valves shall be ball type with a minimum rating of Class 300. The flange
face shall be the ring joint type
□ Isolation valves in stand-alone pressure relief valve inlet and discharge piping shall be gate,
ball, high performance butterfly (flanged) or plug valves that can be car-sealed open. A gate
valve in
this service shall be installed with the stem in or below the horizontal position. For clean gas
service, the valves shall be soft seated with double block and bleed capability if temperature
permits.

□ Isolation valves in flare system piping shall be gate, ball, high performance butterfly or plug
valves .A gate valve in this service shall be installed with the stem in or below the
horizontal position

□ Emergency isolation valves (EIVs) shall be gate, ball, high performance butterfly (flanged) or plug
valves
□ Atmospheric drain and vent valves shall be provided with a plug or blind on the discharge side
□ Flangeless valves shall not be used as the first block valve against storage tanks or
vessels containing hazardous materials
□ Scraper trap mainline isolation valves shall be full bore thru-conduit gate or ball valves.
□ Scraper trap Drain valves shall be inverted pressure balanced lubricated plug valves with Stellite
hardfacing on the plug and body seating surfaces.
□ Scraper trap Kicker valves and vent valves shall be inverted pressure balanced lubricated plug
valves
□ Instrumentation root isolation valves shall be API STD 602 gate valves.
□ Steam service Isolation valves, NPS 2 inch and larger, in Class 600 and higher rated systems
shall be parallel slide gate valves equipped with a cavity pressure relief system
□ Blowdown valves in gas pipelines shall be plug valves
□ Mainline bypass/equalization valves in gas service shall be inverted pressure balanced
lubricated plug valves
□ Monel K-500 may be substituted for Monel 400 where additional hardness or strength
is required
□ Do not use diaphragm valves in dry chlorine service
□ For water services, use PVC up to 50°C. Use CPVC in range between 50°C and 72°C.

❖ Punch list;- List of unfinished or un matched item as per IFC Drawing

17
 ● “A” punch items
1) Any direct welding and NDT balance
2) All in line BT
3) Valve test Report
4) Orifice flange flush grinding and seal welding
5) Arc strikes and Gouges
6) All weld joint, flanged, and threaded joint should be visually exposed prior to hydro test
7) Straightness, plumb out
8) Dead leg, Dog Leg
9) A 6 mm Weep hole should be provided all vertical and horizontal dummy support
10) Internal flapper of welded check valves should be remove
● “B” punch items
1) All Guide supports
2) Orifice plate and jack screw installation
3) All Test limit should be final BT with permanent gasket and bolts
4) All instrument connection
5) FG and Strainer should be installed
6) All check valves and control valves as per process flow direction
7) Internal flapper of welded check valves should be re-installed
8) All spectacle blind and paddles should be installed as per P&ID
9) Pipes are in full contact with the supports.
10) All vents and drains are provided with bar stock plugs or blinds
11) All nuts and bolts of flange connections are fully engaged
12) Relief valve installation
13) Painting
14) Insulation

Contents of Test Package

1) Table of content
2) Flow chart
3) Index
4) Safety instruction sheet
5) Mark-up P&ID

18
 6) Isometric drawings
7) Support drawings
8) GA drawings
9) Weld summary
10) NDE Summary
11) Blind list
12) Valve test report
13) Bolt Torquing flange joint assembly SAIC & SATR
14) Pre-test punch list SAIC & SATR
15) Internal cleaning SAIC & SATR
16) Hydro test SAIC & SATR
17) Calibration Report of PG, RV and Manifold
18) Water analysis Report
19) Lay-up SAIC & SATR
20) Re-instatement SAIC & SATR

Pressure Rating or Class (ASME B16.5/B16.47 Flange Class)

● 1- 150, 3 - 300 , 6 - 600 , 9 - 900 , 15- 1500, 25 - 2500
● 80 - Non-pressure , 90 - Class 3000 API 6A , 95 - Class 10000 API 6A, 99 - Design pressure

Line Material
BC - Copper Tubing
LP - Polypropylene-lined Carbon Steel
BD - 90-10 Cu-Ni
LT - PTFE Lined Carbon Steel
CA - Impact Tested Carbon Steel
NC - Hastelloy C276
CS - Carbon Steel
NM - Monel 400
CG - Galvanized Carbon Steel

19
NR - Incoloy 800
CH - Carbon Steel, PWHT for Process
NT - Carpenter 20 (Alloy 20)
CT - HIC Tested Carbon Steel
PU - CPVC(Chlorinated PVC)
CJ - 1-1/4 Cr-1/2 Mo Alloy Steel
PV - PVC(PolyVinyl Chloride)
CK - 2-1/4 Cr-1 Mo Alloy
Steel SA - 304/304L Stainless
Steel CL - 5 Cr-1/2 Mo Alloy
Steel SC - 304H Stainless
Steel
CM - 9 Cr-1 Mo Alloy Steel
SD - Type 316/316L Stainless Steel
CX -Carbon Steel, Jacketed
SL - 347 Stainless Steel
DC - Cast Iron, Grey
SP - Duplex Stainless Steel UNS S32205/S31803
FE - Glass Fiber Reinforced Epoxy
SJ - 321 Stainless Steel
LC - Cement-lined Carbon Steel
SY - Super Duplex Stainless Steel UNS S32750
LE - Epoxy-lined Carbon Steel
SV - 254 SMO UNS S31254
LH - HDPE-lined Carbon Steel
WA - Reinforced Thermoplastic Pipe
LL - Cladded Carbon Steel
Corrosion Allowance
Symbol Corrosion Allowance
0 Zero
1 1.6 mm (1/16”)
2 3.2 mm (1/8”)
3 4.8 mm (3/16”)
4 6.4 mm (1/4”)
20
 9 Corrosion allowance as noted.

Service

Symbol Service

A Acid
C Caustic
D Drain/Sewer
H Hydrogen
P Process (General Hydrocarbon)
T Wellhead Piping (Owner designator)
U Utility
W Water (Owner designator)
Y Chlorine Gas (Owner designator)
Saudi Aramco Service Codes

Code Service Code Service

A Air NG Natural Gas

MO Mist Oil BBD Boiler Blowdown
AH Acid Hydrocarbon OS Oily Sludge
N Nitrogen BD Blowdown
AS Acid Sewer OW Oily Water
BFW Boiler Feed Water OWS Oily Water Sewer
BS Bio-Sludge P Oil & Oil Products
C Chemical PA Process Air
CA Caustic PE Pond Effluent
CAS Caustic Sewer PG Purge Gas
CAT Catalyst PO Pump Out
CS Chemical Sewer PT Pump Trims
CW Chilled Water PW Process Water
CWR Cooling Water Return R Refrigerants
CWS Cooling Water Supply RL Relief Line
DGA Diglycolamine RLC Cold Relief Line

21
DFW Deaerator Feed Water RLW Warm Relief Line
DMW Demineralized Water RW Raw Water
DSW Distilled Water S Steam
DT Duct Trims SA Sulfuric Acid
DW Drinking Water SC Steam Condensate
E Exhaust Steam SCA Spent Caustic
EIA Emergency Instrument Air SF Sulfur
FG Fuel Gas SO Seal Oil
FGH High Pressure Fuel Gas SOW Sour Water
FGL Low Pressure Fuel Gas SPO Slop Oil
FLO Flushing Oil SR Sewer (Storm)
FO Fuel Oil SW Salt Water
FW Fire Water SWS Sanitary Sewer
GG Gart Gas TPW Tempered Water
H Hydrogen TW Treated Water
HCL Hydrochloric Acid UA Utility Air
HO Hydraulic Oil UW Utility Water
HSG Hydrogen Sulfide Gas VG Vent Gas
IA Instrument Air VT Vessel Trim
LO Lube Oil W Water
ME Methanol WW Waste Water
600C 600 psig H.P. Condensate 150C 150 psig M.P. Condensate
60C 60 psig L.P. Condensate 15C 15 psig L.P. Condensate
600S 600 psig H.P. Steam 150S 150 psig M.P Steam
60S 60 psig L.P. Steam 15S 15 psig L.P. Steam

Chemical or Vapor Phase or Foam Cleaning

The interior of the piping for the following specific services shall be cleaned after hydrostatic pressure
testing to remove oil, grease, preservatives, rust
a) Boiler feed water and steam condensate.
b) Lube oil and seal oil.

22
c) Seal gas supply piping.
d) Steam supply line to turbines.
e) DGA, TEG, and Refrigerant systems.
f) If necessary to meet service fluid quality.

NOTES:- Test pressures less than 85% of SMYS can have relief valves set at 10% above test pressure.

□ Pressure Testing manifold shall be separately pressure tested to at least 1.2 times the system
test pressure but not less than the discharge pressure of the pump used for the pressure
testing.
□ Pressure rating or design of test manifold components (isolation valves, pipe nipples, fittings)
exceed system test pressure by 20%
□ Test Manifold pressure tested to at least 20 percent above test pressure of the system
under test.
The following items shall be excluded from the in-situ pressure testing
o Rotating machinery, such as pumps, turbines and compressors;
o Strainers and filter elements
o Pressure relieving devices, such as rupture disks and pressure relief valves;
o Locally mounted indicating pressure gauges, where the test pressure will exceed their
scale range;
o Equipment that cannot be drained (This includes valve cavities. See Valve Care
o Instrument Devices).
o Other unlisted sensitive equipment (propose exclusion in test package)

❖ Internal Cleaning Methods

1) Water Flushing - Equipment which is sensitive to damage during water flushing shall be
removed, blocked off or isolated. systems shall be flushed using high pressure jet of
rotating hose or rotating nozzle with a minimum Water velocity of 3 m/s. The general
flushing medium shall be plant/ process water or raw water.

23
 o When flushing stainless steel lines, the chloride ion content shall be less than 50 mg/L.
After flushing, the piping systems shall be completely drained, dried to a dew point
below -1°C and protected against corrosion
2) Pneumatic Flushing
Pneumatic flushing with dry air (dew point -1°C or less) or steam with a minimum exit velocity
of 15 m/s. Repeat flushing until cleanliness is verified by observing the absence of any
solids impact on a polished metal target at the exit
3) Pressurized Air Shock Blowing (PASB)

PASB is used to removing trapped liquid in the piping, or to verify cleanliness of small bore pipe
where video inspection is impossible or inadequate due to pipe dimension or configuration
and PASB used for initial cleaning for instrument air, plant air and nitial cleaning of small
bore pipe (less than 2 inch). The air shocking pressure shall never exceed the working
pressure of the system or (115 psi). Repeat PASB until cleanliness is verified by observing
the absence of any solids impact on a polished metal target at the exit

4) Mechanical Scrapers

Mechanical scrapers can be used under the condition that damage to the pipe interior surface
shall not occur.

Notes :- Equipment must be laid-up after hydro testing unless it can be ensured that it will be
returned to service within 30 days from the first introduction of hydro test water to the system.

Lay up Methods
1) Wet Lay up
After Remove the hydro test water from the system. Maintain the system under a positive
pressure between 30 to 50 psig using nitrogen, sweet hydrocarbon gas or hydraulic
pressure of the treated water. Use gauges to monitor the positive pressure in the

24
 system during lay-up with a scale range not exceeding three times the target pressure.
Minimum residual oxygen scavenger concetration in water shall be 20 ppm & maximum
O2 concentration of 10 ppb
2) Dry Lay up
After Remove the hydro test water from the system. Immediately start drying the system
using hot dry air or dew point controlled air to a dew point of -1°C or less reached at
all exit points. Shut in the system, maintain and monitor the pressure during the lay-up
period. When the required dew point is reached, pressurize the system with nitrogen
or sweet gas to the final lay-up pressure of 30 psig .
3) Ambient Lay up
Remove the hydrostatic test water using a positive pressure of nitrogen or sweet gas until no
water drains out of the system. Shut in the system under positive pressure until
commissioning and start-up.
4) Inert Gas Lay-Up

Remove the the hydrostatic test water using nitrogen or sweet gas until no water drains out of
the system. Shut in the system at 2-10% of operating pressure or 50 psig or less with
nitrogen or hydrocarbon gas

5) Other approved gas lay up

Eg:- Vapor-Phase Corrosion Inhibitor (VCI)

When the bulk of the water has been removed, blow vapor phase corrosion inhibitor Cortec
VpCI 309 or equivalent with nitrogen until it is visibly discharged at the bottom of the valve

SAES-L-110 - Limitations on Pipe Joints and Components

□ The maximum size of socket-welded joints in hazardous services shall be 1½-inch for
new construction.

25
 □ The maximum size of socket-welded joints in hazardous services shall be 2-inch for
maintenance, minor field modifications of existing piping systems, and when necessary
to match existing equipment connections.
□ For sour service, the maximum size of socket-welded joints shall be 1-inch.
□ The axial gap between male and female component shall be maximum of 3 mm and
minimum of 1.5 mm. This gap is required prior to welding
□ The use of sleeve couplings shall be limited to cement lined pipe in water services such
as firefighting piping systems and oily water service

The following piping components are not allowed to use in pressure piping systems
a) Caulked joints
b) Soldered, brazed, and braze-welded joints
c) Expanded joints: (They are slip on type of joints using O-ring to seal the pressure.)
d) Bell-type and packed joints

□ The thread joints shall be taper pipe thread (NPT) conforming to ASME B1.20.1
□ In hazardous services, the maximum size of threaded connections shall be 1½-inch for
standard fittings and valves,
□ In hazardous services, the maximum size of threaded connections shall be 2-inch
maximum when required for maintenance, or minor field modifications of existing
piping systems, or to match threaded specialty devices such as scraper signals and
access fittings for corrosion monitoring.

□ Threaded connection shall not be used in hydrogen service.

□ In non-hazardous services, the maximum size of threaded connections shall be 3-inch
for standard fittings and valves,
□ In non-hazardous services, the maximum size of threaded connections shall be 4-inch
maximum on special items such as fire hydrants
Thread Engagement Requirements for Taper Pipe Threads
Nom. Pipe Size Number of Threads Engaged

26
1/2" & 3/4" 6
1" through 1-1/2" 7
2" through 3" 8
4" 10
□ PTFE (Teflon) tape shall not be used for service temperature greater than 204°C on
threaded connections
❖ Seal welding of all threaded joints up to the first block valve is required
in the following services and applications:
a) All hydrocarbons.
b) Boiler feed water, condensate, and steam systems utilizing ASME Class 300 and higher
flange ratings.
c) Toxic materials such as chlorine, phenol, hydrogen sulphide, etc.
d) Corrosive materials such as acid, caustic, etc.
e) Oilfield chemicals (e.g., corrosion inhibitors, emulsifiers, electrolytes, etc.)
f) Piping which is subject to vibration, whether continuous or intermittent

Seal welding is not required for the following services and applications:
a) Thermowells
b) Bar stock plugs downstream of a seal-welded block valve.
c) Special devices such as access fittings and scraper signals.
d) Joints which require frequent disassembly and are located downstream of a seal welded
block valve, e.g., sample connections.
e) Instrument piping downstream of the primary instrument isolation valve.
f) Pipe union ring threads and joints with elastomer o-rings.
g) Threaded joints, downstream of a seal welded root valve, which discharge directly to an open
drainage system or to the atmosphere.
h) Extended body valves with integrally reinforced welding end per API STD 602.

□ PTFE (Teflon) tape or joint compounds shall not be used in threaded connections
requiring seal welding

27
□ For steel piping in hazardous services, threaded and socket welding fittings shall
conform to ASME B16.11 Class 3000, Class 6000 or higher.
□ Pipe unions in hazardous services shall be limited to Class 3000 threaded
□ socket welding forged steel unions in accordance with MSS SP-83. The material shall be
carbon steel per ASTM A105, ASTM A350 or alloy steel per ASTM A182.
□ Pipe unions shall not be installed in the pipe section between the main pipe run and
root valve.
□ Threaded bushings with one size reduction shall not be used. When bushings are
allowed, only hex head steel bushings shall be used. Flush steel bushings are not
permitted.
□ Welding bosses shall be forged steel ASTM A105, ASTM A350 or ASTM A182,.
□ Integrally reinforced welding outlets (such as Weldolets, Threadolets, Sockolets, etc.) in
Class 3000, 6000 or higher.
□ Malleable iron screwed fittings shall conform to ASME B16.3 Class 150 and shall be
galvanized and limited to non-hazardous services, except that pipe unions shall be Class
300.
□ Pipe plugs for use in metallic piping shall be solid body, bar-stock, or forged steel plugs
in accordance with ASME B16.11
□ The material requirements of carbon steel butt weld fittings to: ASTM A234 Grade WPB
and MSS SP-75
□ Crosses are not permitted
□ Laterals shall be used for low pressure system (less than 150 psig) such as flare lines.
□ Branch connections, such as those for drain and vent connections, on tees, elbows and
reducers are not permitted

SAES-310 :- DESIGN OF PLANT PIPING

o Dead Leg : Dead legs leading to internal corrosion shall be avoided at the design
stage Piping sections that are potential for internal corrosion due to flow stagnation
o A section of a piping system meeting the following criteria is considered as a dead leg:

28
 1) When a pipe section is connected to a flowing stream where it is not self-draining
and is not normally flowing.
b) The piping material has the potential for corrosion in service.
c) When the length is longer than three times its pipe diameter, or 1.22 m (4 ft) whichever is
less. The length of the dead leg is the distance measured from the outside diameter of
the header (or run) to the near end of the branch valve
o For branch connections of 1-½ inch NPS and smaller, the length of the dead leg is the
distance measured from the end of the boss to the near end of the valve.
Commentary
o Dog Leg : Due to distortion during welding
o Drip Leg : used to Remove condensate from steam lines
o Intermediate sizes and the sizes: ⅛, ¼, ⅜, 1¼, 2½, 3½, and 5 inches shall not be
used except when necessary to match equipment connections.
o Pipe (excluding stainless steel tubing) smaller than ¾-inch nominal size shall not be used
for hazardous services (including vents and drains) except for instrument connections
o Threaded pipe is allowed up to NPS 2” for existing facilities in hydrocarbon services and
up to NPS 3” for utility piping
o Exemptions to Dead Legs
A section of a piping system meeting the following criteria is not considered as a dead leg even
if it meets the dimensional criteria above:
a) Piping system that is corrosion resistant by its nature.
b) The service is not corrosive and experience has demonstrated such claim.
c) The service is not wet
□ All piping shall be routed and supported to allow access to machinery for operation,
inspection and maintenance. Inlet and outlet isolation block valves around machinery
shall be accessible from grade near machinery.
□ Isolation block valves are required in the inlet and outlet process piping to and from all
machinery. A check valve shall be installed in the discharge line of all pumps. The

29
 check valve shall be located between the machine discharge flange and the discharge
block valve.

□ Pressure connections including isolation valves shall be provided on the inlet and outlet
piping to and from all machinery. The inlet pressure connection shall be located
between the permanent or temporary strainer and the machinery inlet piping flange.

□ Inlet and discharge piping and isolation block valves shall be the same size or larger
than the machinery inlet and outlet nozzle size respectively.
□ Temporary strainers shall be used during the commissioning and initial operating period
of new plants to prevent foreign objects from entering the machinery.
□ Strainer shall be located between the inlet isolation block valve and the machinery inlet
connection not closer than five pipe diameters to the machinery inlet nozzle.
□ Piping vents and drains shall be located in break-out-spools on the inlet and outlet
piping to the machine. These connections shall not be placed in angle sections of
reducers
□ Centrifugal equipment suction line shall have a straight run minimum of five pipe
diameters between the suction flange and first valve, fitting or strainer to ensure stable
and uniform flow at the machinery suction nozzle. The minimum length shall be
calculated using the diameter of the pump inlet nozzle. Vertically suspended double
casing pumps and horizontal self-priming pumps are exempted from this requirement
● Piping Connected to Pump
□ Suction piping shall be designed to prevent the formation of gas or air pockets.
Sufficient venting provisions shall be included.
□ The suction piping shall be sloped a minimum of 10 millimeters per meter (⅛ inch
per foot) toward the pump
□ Reducers used on horizontal suction line shall be eccentric with the flat side on top.
Eccentric reducer with the flat side on top shall be utilized for overhead piping into a top
suction pump. Concentric reducer shall be used on the vertical suction line as required.
□ Suction and discharge piping for vertical in-line pumps shall have adjustable supports

30
□ If strainers are required beyond commissioning and initial operating period, they shall
be “T” or “Y” type with minimum ¼ inch openings and at least 150% flow area
● Piping Connected to Compressor
□ Horizontal reducers installed in the inlet piping to compressors or blowers shall be
eccentric with the flat side on the bottom of the pipe to prevent the accumulation of
any liquids.
□ Suction piping layout for wet gas compressors shall be free of sections where standing
liquid may accumulate and shall slope back toward the suction vessel. Adequate drains
on the piping shall be provided to remove any standing liquids
□ Suction piping to wet gas compressors shall be heat traced and insulated.
□ The suction line to each compressor or blower shall be provided with permanent or
temporary strainer of an adequate strength.
□ Routing of compressor recycle lines shall be designed to be self-draining preventing
liquid from accumulating in piping low points.
□ The anti-surge recycle line shall join the compressor discharge on a piping tee branch,
located as close as possible to the compressor discharge. The anti-surge recycle line
should join the compressor suction line at the suction knock-out drum or suction piping
upstream of knock-out drum in a 45° angled connection directing the recycle flow
towards the compressor.

□ The type of check valve shall be non-slam internal-spring assisted type.

□ Reciprocating compressors suction piping downstream of the suction drums and
pulsation suppression devices of compressors operating at or within 5°C of the gas
saturation temperature shall be heat traced and insulated to ensure that condensation
of liquids does not occur.

□ Positive displacement machinery shall be equipped with a pressure relief device. This
pressure relief device shall be located between the machinery discharge connection and
the first isolation block valve or blind. Pressure relief device discharge piping shall be
routed to a designated system.

31
 □ All pressure piping appurtenances shall be isolated to atmosphere by double isolation
(e.g., double block valves or one block valve with plug or one block valve with blind
flange).

Notes:-

o Above-grade piping shall be supported to provide a minimum of 300 mm clearance

between bottom of the pipe and the finished grade.
o A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe
movement between above ground piping crossing with any structure (including pipe
support structure). This clearance is also required for above ground piping crossing with
another pipe.
o Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of
all sizes, shall be located at a minimum horizontal distance of 610 mm (24 inches) from
any fixed obstruction. This requirement does not apply to that part of the support
which is attached directly to the piping, such as horizontal and vertical dummy
extensions.
o The minimum cover over underground pressure piping shall be 450 mm in unpaved or
paved areas and 750 mm under paved roads
o Rod hangers shall not be used for lines 12” NPS and larger in liquid service or
multi-phase flow
o Saddle-type supports with pads shall be provided for piping 30-inch NPS and larger

Connectors and Color Coding for Plant Utility Stations

Utility Hose Connection Color Code

32
Demineralized Water 1-inch brass Aeroquip 5101 Blue-White stripe
Raw Water 1-inch brass Aeroquip 5101 Blue
Air ¾-inch iron Dixon Air King AM-8 Green/Gray stripe
Steam 1-inch steel Dixon Boss Wf-36 White
Nitrogen 1-inch steel wing nut union Green/Orange stripe

o Hose connections positioned at elevation shall be 600 mm to 1200 mm. They shall be
pointing 45 degrees downward. The piping shall be securely bolted to a supporting
structure and have adequate access.
o Utility connections shall be installed with minimum 150 mm clearance between each
other.
o Each utility take-off connection shall be located at the top of the horizontal main header
or auxiliary header.
o Root valves shall be provided for each utility take-off connection from a main header or
auxiliary header
o Instrument air take-off connections to the plant utility station shall always be provided
with root valves.
o Each utility line shall be provided with an isolation valve just upstream of the specified
hose connector and Ball or globe valves shall be used for air, water,
In nitrogen service, globe or angle valves shall be used for steam service,
o Each line shall have a service name plate in Arabic and English indicating the service.
o The utility pipe and the ends of hoses provided with the station shall be color coded.
o The steam line shall have a steam trap and shall be insulated for personnel protection
except for utility steam take-off lines.
o Utility steam take-off lines shall be insulated but shall not be provided with steam traps.
Utility steam stations located above the utility steam header shall be self-draining
o The utility side shall have a block (root) valve, pressure gauge, check valve and a drain
valve to depressurize the hose or the break-away spool.

33
 o The process side shall also have a check valve, block valve and pressure gauge near the
hose connection. When disconnected, both open piping ends shall be capped, or
plugged, or fitted with blind flange

SAES-A-004 :- GENERAL REQIUREMENTS OF PRESSURE TESTING

Category D Fluids : fluids which are nonflammable, nontoxic and fluids which are not damaging
to human tissue on contact.

Category M Fluids :- fluids which are flammable, toxic and fluids which are damaging to human
tissue on contact.

Pressure Test : A test conducted by using liquid or gas to build up an internal pressure to
ensure strength or tightness of the system at the test pressure.

Hydrostatic Test: A pressure test conducted using water or other approved liquid as the test
medium.

Pneumatic Test: A pressure test conducted using air or other approved gas as the test medium
or in conjunction with liquid

Service Test : A pressure test conducted at operating pressure using the service fluid

Leak Test: A pressure test to ensure tightness of flanged and threaded joints at the test
pressure.

Strength Test: A pressure test at an internal pressure determined in accordance with standard
and the applicable Code to verify the integrity of the piping systems for service at the design
pressure

Revalidation Test: A pressure test performed to prove the integrity of existing pipelines or
plant piping

Tightness Test: A pressure test to ensure tightness of the piping system (i.e., no leaks in the
system) at the test pressure

Pressure Test procedure

34
o An approved test procedure shall be available at the site prior to pressure test
o A minimum of two pressure gauges are required for the test system. One pressure
gage shall be on the test manifold and the others on the test system. Their accuracy
shall be within 5% of one another. When the system is larger two more gauges are
required. The calibration interval shall not exceed one (1) month prior to the test date
and calibration certificates shall be available at site. Stickers shall be applied indicating
the latest calibration date. All gauges shall have a range such that the test pressure is
within 30 to 80% of the full range.
o 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 valve sealed open during the test. Relief
valve(s) of adequate capacity are set to relieve at 5%* above the hydro test pressure. .
The calibration interval shall not exceed one (1) week prior to the test date and
calibration certificates shall be available at site. Stickers or TAG shall be applied
indicating the latest calibration date.
o A bleed valve shall be provided to protect the piping and equipment from overpressure.
The bleed valve shall be readily accessible in case immediate depressurization is
required.
o Blind flanges, paddle blinds or spectacle blinds shall be used to isolate the test sections.
They shall be the same class rating or higher of the system
o All in-line valves if not used as test isolation valves shall be in a partially open position
o When a block valve is used for isolating test sections, the differential pressure across
the valve seat shall not exceed the seat test pressure during pressure testing
o check valve has a by-pass valve, the disc of the check valve shall be removed, and
securely attached to the outside of the check valve prior to the pressure test.
o All vents shall be open during filling
o Filling and pressurizing shall be done on the upstream side of check valves in the
system. The test fluid shall be injected at the lowest point in the system

35
 o After reached the Test pressure, The isolation valve between the test manifold and
pump shall be closed and the test pump disconnected. The isolation valve downstream
of the manifold shall be opened after the pump is disconnected

Note :-

□ The maximum CS equipment contact time with hydro test water shall be 14 days from
the first introduction of water
□ Equipment must be laid-up after hydro testing unless it can be ensured that it will be
returned to service within 30 days from the first introduction of hydro test water to the
system.
□ The maximum SS equipment contact time with hydro test water shall be 4 days from
the first introduction of water
□ At end of lay-up, commission & start up heat exchangers shall be within 14 days, &
other equipment within 60 days
□ Type 300-series stainless steel systems shall be tested only with water having maximum
allowable chloride concentration of 50 ppm
□ Sulfate Reducing Bacteria (SRB) count of 10^3 per ml or less as determined by the
Rapid Chek II Method
□
Treatment of Hydrostatic Test Water

When CS equipment contact time with hydro test water exceed 14 days and SS equipment
contact time with hydro test water exceed 4 days an approved oxygen scavenger shall be
added to the hydrostatic test water. Treat water before it enters the system. Use batching
scrapers and or a slug of nitrogen to separate the air in the system from coming in contact with
treated water, then fill systems with water injecting sufficient oxygen scavenger to maintain its
residual concentration at greater than 20 ppm & an oxygen concentration of less than 10 ppb

□ 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 (ga) (100 psig) whichever is the greater

36
 □ Underground process piping shall be tested prior to backfilling. The test pressure shall
be maintained for a minimum of 2 hours
□ If the must be back-filled, 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 (75 psig) or lower may be
pneumatically strength tested
□ Piping in vacuum service shall be pressure tested to 1.5 times the differential external
pressure not less than 100 kPa (ga) (15 psig)

❖ Service test is acceptable for the following services:

a) Plant utility piping in air and inert gases services with a designed pressure and equal to less
than 035 kPa (ga) (150 psig).

b) Low pressure steam piping designed for 60 psig or less

❖ Low pressure steel piping in water, instrument air, plant air, inert gas (Nitrogen, Argon,
etc.), and steam systems operating at 1035 kPa (ga) (150 psig) or lower, may be strength
tested with its own product at its operating pressure (service test).
❖ Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 35 to 70 kPa (ga) (5
to 10 psig) in the annulus between the gasket and the seal weld. It shall be examined
for leaks using a soap solution

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Air Gap: An air gap is the unobstructed vertical distance through the free atmosphere from the
lowest opening from any pipe, equipment, Air gap shall be a minimum of 25 mm (1
inch) and shall not exceed 100 mm (4 inch).

□ Orifice flanges up to 24 inches shall be in accordance with ASME B16.36 and ANSI
2530/API 14.3/AGA-3.
□ Orifice flanges larger than 24” can be based on ASME B16.47
□ In process piping , Orifice flanges shall be rated at a minimum of ASME/ANSI Class 150.
□ For liquid and steam services, pressure taps shall be located on the horizontal side of
the piping or up to 45 degrees down from horizontal. The impulse lines shall be sloped
downward approximately 1:12 toward the transmitter
□ For gas and vapor services pressure taps shall be located on the vertical from the top of
the piping, or up to 45 degrees from top. The impulse lines shall be sloped downward
approximately 1:12 toward the process connections
□ All parallel pipe lines with adjacent orifice flanges or orifice fittings shall have a
minimum spacing of 300 mm (12 in) between flanges outside diameters if horizontal
taps are required. In addition, they shall be staggered so that no two pairs of orifice
flanges (centerline to centerline) are less than 1 m (3 ft) apart
□ Interconnecting impulse tubing between a differential flow element and a transmitter
shall be limited to a maximum length of 6 m (20 ft) for flow meters used in control
loops.
□ Flow measurements requiring temperature compensation thermos wells shall be
located between 5 to 20 nominal pipe diameters downstream of the meter

Orifice plate installation

o Flange taps shall be used for all orifice meter installations
o Paddle type orifice plates shall be used where raised face orifice flanges are used.
o Orifice plate shall be stamped with the Instrument Tag Number of the element, the
element location in the pipe, the pipe internal diameter and the direction of flow
o Drain or Vent hole for Vertical Meter Run – No hole
o Horizontal Meter Run, Wet Gas or Saturated Steam – One drain hole, bottom location.
o Horizontal Meter Run, Gas Entrained Liquid service - One vent hole, top location.

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