SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005

)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Pre-Test Inspection of Pressure Vessels (All Applications, Including In-situ Testing of New Fin Fan Coolers)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2025
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL

EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER

EQPT CODE

SYSTEM ID.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME

ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO USE ONLY
WORK PERMIT REQUIRED?

ITEM No. A

ACCEPTANCE CRITERIA Test Package Verification: Test Diagram is submitted showing the following: A) Limits of equipment to be tested incl. test manifold & equipment included in the test. B) Test pressure of the system C) Relief valve setting D) Safety Instruction Sheet Procedure has been approved & meets the detailed requirements of SAIC-A-2001 (Review Procedure - Pressure Testing) Verify drawing conformance of pressure vessel construction. Check all nozzles, supports, attachments (orientation & dimemsion) Systematically complete, verify & accept all drawings incl. details Verify complete code construction incl. support attachments. Repairs & Pick-up (ID/OD) are accepted. ASME VIII, UG-99 (a) Weld Summary Record (SAEP-1160 Welding Database) was verified to indicate completion/acceptance of all weld joints, repairs, modifications & any applicable weld inspection reqmts (visual, NDE). Verify SAIC-W-2008 & SATR-W-2008 details as applicable All required inspection & testing (RT, MT, PT, PWHT, PMI) has been completed & inspection control sheet has been signed by SA. (ASME VIII, UG-99, Para. A-2) As applicable, an SAEP-1160 Welding Database is reviewed Safety Instruction Sheet (SIS) for vessesl/equipment is complete & approved. Verify correct test pressure for system/equipment. Test Pressure at top of vessel is verified against the SIS and conforms to the following ASME Section VIII code, as applicable: A) 1.3 times MAWP for ASME D1 vessels per UG-99 (b) B) 1.25 times MAWP for ASME D2 vessels per AT-301, Div 2 Field Verification/Pre-Test Inspection of Vessel Vents are provided at all high points in the position in which it is to be tested to purge all possible air during water filling. Vessel must be adequately supported during hydrotest if it is tested out of position The strength of existing foundation/supports shall be confirmed to be adequate for additional weight of hydrotest fluid. All joints and faying surfaces, except those specifically designed and designated as removable bolted connections, are seal welded by a continuous fillet weld (external weep holes are left unwelded). Weld Summary Record was verified to indicate completion of all weld joints & applicable weld inspection reqmts (visual and NDE). Post Weld Heat Treatment (PWHT) is complete.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

A1

SAES-A-004, Para. 5.6.1

A2

SAES-A-004, Para. 7.1.1 Contract drawings 32-SAMSS-004, Section 16.3.1 SAEP-1160 & SAES-W-010, Para 16.1.2

A3

A4

A5

A6

32-SAMSS-004, Section 16.3.1

A7

SAES-A-005, Para. 4.2 SAES-A-004, Para. 6.3.1 & 32-SAMSS-004, Section 16.3.8

A8

B

B1 B2 B3

ASME VIII, UG99, Para.(i) SAES-A-004, Para.6.3.1 SAES-A-004, Para.6.3.1 SAES-W-010, Para. 11.15.1 SAES-W-010, Para. 15.2 32-SAMSS-004, Section 16.3.2

B4

B5

B6

Page 1 of 3

3. 2005) 7. Alterations. glues.2. etc. Para. Including In-situ Testing of New Fin Fan Coolers) PROJECT TITLE 31-Dec-05 DATE APPROVED QR NUMBER SAIC-A-2025 WBS / BI / JO NUMBER 1-Dec-06 MECH- CONTRACTOR / SUBCONTRACTOR ITEM No. Telltale holes are OPEN during pressure test. SAES-A-005. Section 16.6 32-SAMSS-004.3 32-SAMSS-004. scale.3 SAES-L-150. Manufacture of Pressure Vessels (30 March. 5. grit. (28 February 2005) 3. Safety Instruction Sheet. Note: Vessel Trim piping pressure tests are often overlooked Sampling piping systems are pressure tested as an integral part of the equipment to which it is connected. B7 ACCEPTANCE CRITERIA Prior to final inspection & pressure test. SAES-A-004. All welded attachments with telltale holes shall be pneumatically tested at minimum 35 kPa (5 psi) prior to heat treatment and vessel pressure testing.Rules for Construction of Pressure Vessels (2002 Edition) 8.3.4 32-SAMSS-004. (e)] REFERENCE 32-SAMSS-004.4. spatter. 6. Gaskets and bolting materials are as specified on data sheet. etc. Section 16. Pressure Testing of Plant Piping and Pipelines (30 September. Section 16. Horizontal vessels shall be tested while resting on their permanent support saddles without additional supports or cribbing. new vessel internal and external surfaces have been thoroughly cleaned. dirt. paint. This is a Bubble Leak test per SAIC-A-2005/A-2021/A-2023 Shellacs. 5. example: Sumps. A) Inner vessel construction & hydrotesting is completed prior to outer jacket installation and hydrotesting. 2003) 5 SAES-W-010.SAUDI ARAMCO ID/PID . lead. Note: Gaskets may be used as service gaskets if the bolted joint is not disassembled after testing. Fin fan exchangers are strength tested in-situ before final acceptance for all new projects. Section 16. oil. General Requirements for Pressure Testing. Repairs. See Attachment 1 Jacketed Vessel exams & hydrotest sequence are planned and detailed in design & during hydrotesting (per test procedure). Any slag.December 2005) Rev 2 SAIC NUMBER SAUDI ARAMCO INSPECTION CHECKLIST Pre-Test Inspection of Pressure Vessels (All Applications. Organization.1 SAES-A-004. Equipment or parts that are clad shall be hydrotested with water having chloride content not greater than 50 ppm.18-MAY-05 . Attachment VI PROCEDURE DETAILS REMARKS: REFERENCE DOCUMENTS: 1. 2003) 4.12 32-SAMSS-031. HOLD POINT. SAES-L-150. Welding Requirements for Pressure Vessels (14 November 2005) 6. Initials and Date: Name. Initials and Date: QC Record Reviewed Work Verified QC Supervisor Quality Record Approved: Name. and Re-rating of Process Equipment (30 November. ASME Section VIII. [Reference: ASME VIII. Jacket design & installation is carefully planned.3 32-SAMSS-004. SAES-D-008.are not applied on gaskets during testing.Rules for Construction of Pressure Vessels. Section 16.5. (30 March.3. 10. B) Construction sequence allows 100% visual inspection of welds during hydrotest.1 PASS FAIL N/A RE-INSP DATE B8 B9 B10 B11 B12 B14 B15 B16 B17 B18 SCH Q. UG-99 sect.3. Vertical vessels tested in horizontal position are supported such that primary stresses in any part of the vessel do not exceed 90% of minimum specified yield strength of the vessel material.3. Section 16. 2005) 2. Para. Vessel Trim (associated piping) receives a strength test except in Utility services and less when a service test can be conducted.11 32-SAMSS-004. Initials and Date: Saudi Aramco PMT Representative T&I Witnessed QC Record Reviewed Work Verified QC Inspector Performed Inspection Name.REV 0 (Standards Cutoff .2. 32-SAMSS-004. Initials and Date: Work / Rework May Proceed PID Representative T&I Witnessed Name. Sign and Date: *Person Responsible for Completion of Quality Work / Test Proponent and Others Name. Division 2 . Division 1 . Alternative Rules (2002 Edition) Contractor / Third-Party Construction Representative* Work is Complete and Ready for Inspection: Name. ASME Section VIII.9 SAES-L-150. Initials and Date: T&I Witnessed QC Record Reviewed Work Verified Y = YES N = NO F = FAILED Page 2 of 3 . Para. Para. and construction aids are removed.

bowed . VERY STRAIGHT! b) If they aren't straight. 32-SAMSS-011. 11 4. Sect.. b) NEVER exceed more a few meters between blocks.1 kg/m³ fogged into the space. NEVER ALLOW FORK TRUCK UNLOADING. Follow these simple guidelines to assure good test results..IN-SITU TESTING & CARE OF FIN FAN COOLERS 1. i. Limit opening for "fit up" & piping work to good dry weather. 8. Page 3 of 3 ..e. OR YOU CAN COUNT ON ADDED COST DUE TO TUBE/TUBESHEET LEAKS!!! 5. suitable for its intended use & not result in crevice corrosion.. Sect. Make sure extra support is there & level. utilize this opportunity to meet the reqmt. 11 Stainless steel exchangers shall be protected from salt water and salt water spray during shipment. YOU DIDN'T DO SO WELL .. If Chemical Cleaning (usually around 90 psi) is req'd. *PLAN Proactive supervision at handling points to assure they arrive ok. Make certain Fin Fans (on arrival) were treated very carefully. beware of opening these up. specifically the tube supports. 10. Including In-situ Testing of New Fin Fan Coolers) 31-Dec-05 DATE APPROVED QR NUMBER SAIC-A-2025 1-Dec-06 MECH- Attachment 1 . 2.18-MAY-05 . Water removal after testing at low points can be assured by spool dropouts.. (it's usually close enough) Perform testing in accordance with good lay-up practices. MAJOR PROBLEM! c) Don't even let it be unloaded BEFORE YOU TAKE PICTURES. Alternatively. before it leaves the truck it arrives on! Inspection (camera) a) Look at the top row of tubes.December 2005) Rev 2 SAIC NUMBER SAUDI ARAMCO INSPECTION CHECKLIST Pre-Test Inspection of Pressure Vessels (All Applications. ALWAYS HAVE EXTRA PLUGS ON HAND (OR OVERNIGHT ACCESS AVAILABLE) IN THE EVENT OF TUBE/TUBESHEET LEAKS. Test as close to start-up as practical. Exchangers must be sealed vapor tight for the inhibitor to be effective. Fin Fan Coolers can "twist" if improperly lifted. 6.. 3. First thing. Inspect the load on arrival for proper preservation & damage The internals of exchangers shall be protected from corrosion by use of a non-toxic vapor phase corrosion inhibitor such as CORTEC VCI-309 or 307 or equivalent. d) Look at underside of the tubes. 32-SAMSS-011. 7.. Corrosion Inhibitors can solidify. YOU MADE IT THIS FAR OK . * All the Quality intentions in the world won't fix a badly mishandled Fin Fan Cooler. Transit & erection clips & fasteners are checked closely for damage. MAKE YOUR CLAIM RIGHT AWAY! TAKE EXTRA* PRECAUTIONS! * The first one arrived damaged . a) Use good blocks (no nails). 12. Corrosion inhibitors for use on exchangers with stainless steel & monel tubes must be chloride free.REV 0 (Standards Cutoff . Plan staging areas close to Units to minimize handling OK. Be Prepared to pull plugs and allow Proponent a visual exam. Keep system closed except when absolutely necessary. Plan Test at test pressure on Manufacturer's Stamp. applied at a rate of 0. Follow detailed manufacturer handling and preservation requirements . They should be VERY. NOW PRESERVATION EFFORT 9. BEWARE!!! Properly equipped cranes with "spreader" bars are used for unloading.SAUDI ARAMCO ID/PID . ORDER EXTRA PLUGS & PRAY!!! OK. YOU CAN COUNT ON ALL OF THEM COMING THIS WAY "UNLESS YOU ACT QUICKLY". e) Severe shipping damage will result in "dislodged" support members. nitrogen blanketing or temporary coatings in accordance with MIL-C-16173-D Grade IV (example Tectyl 846) may be used. 11. UNLOAD & STORE ON HARD & EXTREMELY LEVEL SITES ALWAYS.. The inhibitor selected must be appropriate for the metallurgy of the exchanger...

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