Safety Instruction Sheets For Plant Piping and Cross-Country Pipelines PDF

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
SAFETY INSTRUCTION SHEETS FOR PLANT

PIPING AND CROSS-COUNTRY PIPELINES
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Mechanical
File Reference: MEX-101.10
For additional information on this subject, contact

PEDD Coordinator on 874-6556
Piping, Pipelines & Valves

Safety Instruction Sheets for Plant
Piping and Cross-Country Pipelines
MODULE COMPONENT
PAGE
INTRODUCTION .................................................................................................2
DETERMINING THE INFORMATION REQUIRED FOR PLANT PIPING............4
Critical Plant Piping Systems ....................................................................4
Information Contained in Saudi Aramco Form 2821 .................................5
DETERMINING THE INFORMATION REQUIRED FOR CROSS-COUNTRY
PIPELINES ..........................................................................................................7
Information Contained in Saudi Aramco Form 5645-1 ..............................7
Information Contained in Form 5645-1, Cont'd .........................................8
Information Contained in Saudi Aramco Form 5645-2 ..............................9
SUMMARY ........................................................................................................10
Line Identification (Entries 1-6)................................................................11
Equipment Data (Entries 7-16)................................................................11
Operating Limits (Entries 17-28) .............................................................13
Miscellaneous Information (Entries 29-35) ..............................................16
Work Aid 2A: Saudi Aramco Form 5645-1............................................18
Pipeline Identification (Entries 1-12)........................................................18
Equipment Data (Entries 13-24)..............................................................20
Work Aid 2B - Saudi Aramco Form 5645-2 .............................................27
Pipeline Identification (Entries 1-9)..........................................................27
Equipment Data (Entries 10-20)..............................................................28
Operating Limits (Entries 21-37), Cont'd .................................................29
Operating Limits (Entries 21-37), Cont'd .................................................31
GLOSSARY .......................................................................................................34

INTRODUCTION
Safety Instruction Sheets are used to ensure that
operations, maintenance, and inspection personnel will
have adequate information that concerns safe operating
limits, protective devices, any special safety precautions
for specified piping system or pipelines, and other
equipment items in a consistent format. The Saudi
Aramco engineer must know how to complete all the
items on the applicable Safety Instruction Sheet,
including Maximum Allowable Operating Pressure
(MAOP), pipewall thickness, pressure test requirements,
and numerous other items that were previously
discussed in this course. The Saudi Aramco engineer is
responsible for the completion of the form, the audit of
the contents of the form, and ensuring that it is included
in the design package.
The Safety Instruction Sheets applicable to piping
systems are as follows:
Saudi Aramco Form 2821.
Saudi Aramco Forms 5645-1 and 5645-2.
Saudi Aramco Form 2821 is used for plant piping

systems, and Forms 5645-1 and 5645-2 are used for
cross-country pipelines. The extent of their use for these
systems will be discussed in later sections. These forms
provide a permanent record of critical data with regard to
the piping system. In particular, pipe material, design
conditions, thicknesses, MAOP, and safety-valve set
pressures are specified on these sheets. By the time
these forms are completed, the piping system design has
been done, and all the information that is necessary to
complete these forms is readily available. Thus, no
additional engineering is required to complete these
forms.
An engineer can obtain a fairly complete picture of the
design of the piping system from the Safety Instruction
Sheets. The Safety Instruction Sheets are part of the
permanent records for the system and are a critical

resource when changes or maintenance are required on

the piping system. These forms must be completed
before the system is put into operation. They are
completed throughout the design of the piping system,
and they are referred to during inspection and testing.
Saudi Aramco Engineering Standard SAES-A-005,
Safety Instruction Sheet, provides requirements and
instructions for the completion of the appropriate form for
a particular situation. SAES-A-005 should be referred to
when a Safety Instruction Sheet is being completed.

DETERMINING THE INFORMATION REQUIRED FOR PLANT PIPING

Critical Plant Piping Systems
SAES-A-005 requires that Safety Instruction Sheet,
Saudi Aramco Form 2821, be completed for critical plant
piping. A piping system is determined to be critical based
on operational considerations, design conditions that
make it more difficult to design and/or prone to failure, or
safety considerations. A plant piping system is critical if it
meets at least one of the following criteria:
The failure of the system would lead to a major

shutdown of the plant, or shutdown of a major unit
of the plant.
The design temperature is 340C (650F) or higher.
The design pressure is 3,450 kPa (500 psig) or

higher.
The fluid that is contained in the pipe is toxic or very

corrosive.
There is some other specific operating hazard

associated with the system that is not normally
experienced with the usual plant or process lines.
Saudi Aramco Form 2821 is normally not completed for

piping systems that are covered by Piping Material
Specification Classes D, E, F, G, or H of SAES-L-005.
These Specification Classes are relatively mild in nature,
as follows:
Class D Low-Pressure Utilities, Noncorrosive
Class E Low-Pressure Utilities, Corrosive
Class F Nonpressure Sewers
Class G Small Diameter Piping Around Pumps

and Compressors
Class H Low-Pressure Hydrocarbon Service
Refer to SAES-L-005 for the specific service limitations of

these Classes.

Information Contained in Saudi Aramco Form 2821

Saudi Aramco Form 2821 identifies system design
information for plant piping systems. The design
information that is identified on Saudi Aramco Form 2821
must be determined in order to complete the form. Work
Aid 1 contains a copy of Form 2821 (Figure 1) with each
entry area numbered. Work Aid 1 also contains a
procedure that may be used to complete the form and is
keyed to the numbered areas. Form 2821 identifies four
primary categories of information as follows:
Line Identification Information. These items

identify the line with respect to line number, end
points, fluid service, other reference drawings, and
the industry code that was used for its design.
Equipment Data. These items define the primary

physical design information for the system, such as
diameter, nominal wall thickness, material, and
flange rating. This information helps personnel
define many of the physical characteristics of the
system without the need to locate the detailed
engineering drawings. Additional needed
information can be found as required because the
design drawings are also referenced. All of this
information was determined during the system
design and most was discussed in earlier modules
of MEX 101.

Operating Limits. These items define the primary

operating limits for the system, such as design
pressure and temperature, MAOP, test pressure,
and the component(s) that limit the system
operation. This information permits personnel to
perform an initial evaluation of the system to
determine its limitations. This may be required if a
rerate is being considered, or if corrosion has
occurred. All of this information was determined
during the system design and most was discussed
in earlier modules of MEX 101.
Miscellaneous Information. This section contains

additional information regarding location,
identification, and locations for the necessary
approvals.
Refer to Work Aid 1 and Figure 1 for the specific

information that is contained in each of these categories
and for a procedure for completing this form.

DETERMINING THE INFORMATION REQUIRED FOR CROSS-COUNTRY

PIPELINES
In general, Safety Instruction Sheets are prepared for all
flowlines, trunklines, and cross- country pipelines that
carry any fluid. Saudi Aramco Form 5645-1 shall be
completed for all major pipelines. In addition, Saudi
Aramco Form 5645-2 shall be filled out for the same
pipelines to cover tie-in piping, scraper traps and their
appurtenances, jumpovers, flanges, fittings, any special
components, road crossings, and sun pressure relief
valves. Form 5645-2 shall also be prepared for flowlines,
trunklines, testlines, and submarine pipelines. Both
Forms 5645-1 and 5645-2 are to retain the same Saudi
Aramco drawing number when they are used for different
portions of the same general pipeline, but with different
sheet numbers.
When calculations are required to complete the form, the
issuer of the forms must attach a calculation sheet with
each form to help with any later review that might be
required. The calculation sheet shall show the method
that was used to achieve calculated values, such as
formulas, individual variables that are in the formulas with
their units, specific requirements from the relevant
standards, etc.
Information Contained in Saudi Aramco Form 5645-1
Saudi Aramco Form 5645-1 identifies system design
information for cross-country pipelines. The design
information that is identified on Saudi Aramco Form
5645-1 must be determined in order to complete the
form. Work Aid 2A contains a copy of Form 5645-1
(Figure 2) with each entry area numbered. Work Aid 2A
also contains a procedure that may be used to complete
the form and is keyed to the numbered areas. Form
5645-1 identifies four primary categories of information
as follows:
Pipeline Identification Information. This includes

items such as the pipeline's official designation, end
points, fluid service, the year it was built, valve

operating diagram reference, the number of sheets

that describe the entire pipeline, reference to the
Forms 5645-2 that are also used for the pipeline,
and the pipeline segment numbers that are covered
by the sheet.
Equipment Data. These items define the primary

physical design information for the pipeline
segments that are covered by a particular sheet.
This includes items such as diameter, nominal wall
thickness, material, flange rating, and whether the
pipeline is buried or aboveground. This information
helps personnel define many of the physical
characteristics of pipelines without the need to
locate the detailed engineering drawings or go into
the field. All of this information was determined
during the pipeline design, and most was discussed
Information Contained in Form 5645-1, Cont'd
Operating Limits. These items define the primary

operating limits for the pipeline. This includes items
such as the MAOP of each segment and the overall
system (and the component[s] that limit them), the
Design Factor of each segment, maximum design
temperature, minimum tie-in temperature, minimum
required thickness, and test pressure. This
information permits personnel to perform an initial
evaluation of the pipeline to determine its limitations.
This evaluation may be required if an alternate
operation is being considered, or if corrosion has
occurred. All of this information was determined
during the system design, and most was discussed

Miscellaneous Information. This area contains

additional information regarding location,
identification, and locations for the necessary
approvals.
Refer to Work Aid 2A and Figure 2 for the specific

information that is contained in each of these categories,
and for a procedure for completing this form.
Information Contained in Saudi Aramco Form 5645-2
Saudi Aramco Form 5645-2 identifies system design
information for flowlines, trunklines, testlines, submarine
pipelines, tie-in piping, scraper traps and their
appurtenances, special components, and the other items
that were noted previously. Work Aid 2B contains a copy
of Form 5645-2 (Figure 3) with each entry area
numbered. The design information that is identified on
Saudi Aramco Form 5645-2 must be determined in order
to complete the form. Work Aid 2B also contains a
procedure that may be used to complete the form and is
keyed to the numbered areas.
Saudi Aramco Form 5645-2 identifies the same four
primary categories of information that were discussed for
Saudi Aramco Form 5645-1. However, the specific data
items that are included in the "Equipment Data" and
"Operating Limits" categories are more similar to the
items that are in Form 2821 for plant piping rather than in
Saudi Aramco Form 5645-1; the similarity exists because
the particular pipeline system items for which Saudi
Aramco Form 5645-2 is used are more similar to plant
piping than to cross-country pipelines.
Refer to Work Aid 2B and Figure 3 for the specific
information that is contained in each of these categories
and a procedure for completing this form.

SUMMARY
Safety Instruction Sheets must be completed before a
piping system can go into operation. For critical plant
piping systems, Form 2821 must be completed. For
cross-country pipelines, Saudi Aramco Forms 5645-1
and 5645-2 must be completed. The completion of these
forms requires the engineer to collect information
regarding system design and operating limits that has
already been determined during detailed engineering.
The collection of data in this manner ensures that
operations, maintenance and inspection personnel have
adequate information in a consistent format.
The next module discusses how to maintain piping and
repair defects after the piping system has been placed in
operation.
10

WORK AID 1:
PROCEDURES FOR DETERMINING THE INFORMATION TO

COMPLETE A SAFETY INSTRUCTION SHEET FOR PLANT
PIPING
Use the following procedure, in conjunction with Figure 1,
to determine the information that is necessary to
complete Safety Instruction Sheet, Form 2821, for critical
plant piping. The identification numbers that are shown in
the following procedure correspond to those shown in
Figure 1. Reference SAES-A-005, Safety Instruction
Sheet, for additional information. Note that by the time it
is necessary to complete Form 2821, engineering has
been completed, all the required information is readily
available, and no new calculations or selections are
needed.
Line Identification (Entries 1-6)

1.
Show the line identification number, such as P28-3A1.
2. & 3.
Indicate where the line starts and ends, such

as Furnace F-201 to Column C-221, Acid
Pumps G-21A/B to Reactor D-21.
4.
Give specific data on the fluid service, such as

reduced crude with acid, vapor, etc.
5.
Indicate the pertinent pipe isometrics, P & ID's,

or other reference drawings that apply to the
particular line.
6.
Show the applicable industry code and year

that was used in the pipe design, such as ANSI
B31.3, 1990.
Equipment Data (Entries 7-16)

Note that there are three columns within the Equipment
Data area. This permits providing information about
three separate pipe sizes or materials that may be within
11

the same piping system.

7.
Nominal pipe size (NPS).
8.
Pipewall thickness in inches or millimeters.

Note that this is the nominal pipe thickness,
which was discussed in MEX 101.03.
9.
Pipe material specification and grade, such as

A-106, Gr. B, API 5L, Gr. X-42. Material
selection was discussed in MEX 101.02 and
MEX 101.08.
Equipment Data (Entries 7-16), Cont'd

10.
Indicate whether the pipe has a welded

longitudinal seam (such as SAW, ERW), or is
seamless (SMLS).
11.
Flange rating according to ASME/ANSI B16.5.

Selection of the required flange rating was
discussed in MEX 101.04.
12.
Type of flange face, such as raised face (RF),

ring joint (RTJ), or flat face (FF). Flange face
requirements were discussed in MEX 101.04.
13.
Flange material specification and grade, such

as A-105; A-350, Grade LF-2. Flange material
selection was discussed in MEX 101.04 and
MEX 101.08.
14.
Fitting rating, such as Sch. 40 for butt-weldtype fittings, or 3,000 lb. for threaded- or
socket-welded-type fittings. The rating of pipe
fittings was discussed in MEX 101.04 and MEX
101.08.
15.
Fitting material specification and grade, such

as A-105; A-234, Gr. WPB. Fitting material
specification was discussed in MEX 101.04
and MEX 101.08.
16.
Any specific remarks with regard to material,
12

components, system limitations. Include items

such as the following:
Precautions that are necessary during

operation or tests. For example, the need
to blind-off expansion joints during
hydrostatic tests because they will not
withstand the test pressure, or the need to
add temporary supports during hydrotest.
Special piping components that may be in

the system, such as soft-seat ball valves.
Operating Limits (Entries 17-28)

17. & 18. Indicate the MAOP and temperature for the
lines as one system based on its weakest
point, such as the corrosion condition of the
line, pressure vessels, flanges, etc. MAOP
was discussed in MEX 101.03 and MEX
101.04.
19.
Enter the actual new test pressure. The test

pressure should be consistent with the
hydrostatic test diagram and SAES-A-004.
Test pressure requirements were discussed in
MEX 101.09.
13

Operating Limits, (Entries 17-28), Cont'd

20.
Show the limiting item for the test pressure,

such as flanges, pipewall thickness, pressure
vessel, heat exchanger.
21.
Enter the design pressure, which should be

consistent with SAES-L-002.
22.
Enter the design temperature, which should be

consistent with SAES-L-002.
23.
Indicate the limiting item for the design

pressure, such as pipewall thickness, flanges,
process limitations, or any other limiting item.
24.
Enter the equipment safety valve set pressure,

not greater than that shown under Key Number
21.
25.
Nominal Pipe Size (NPS). Note that there are

three columns for size and for Key Numbers 26
and 27. This permits providing information
about three separate pipe sizes that may be
within the same piping system.
26.
Required minimum wall thickness, tm, for the

pipe. Refer to ASME/ANSI B31.3 and MEX
101.03 for method of calculation.
Note that tm is the retirement wall
thickness, and shall also not be less than
the required wall thickness for mechanical
strength. Refer to Saudi Aramco
Inspection Procedure 01-AIP-02-0, SAESL-006, or the piping specialist in the
Consulting Services Department, for
further explanation. When tm is for
mechanical strength, indicate this in the
remarks section.
27.
This is calculated based on the nominal wall

thickness of the pipe, minus manufacturing
undertolerance for thickness, and minus the
14

value that was determined for Key Number 26.

Note that the corrosion allowance, c, as
determined here, is the remaining pipewall thickness that is above the required
tm. 'c' is not the required corrosion
allowance that was specified as part of
the initial design conditions for the piping
system. If a corrosion allowance is
required, it must be stated in the remarks
area under Key Number 28.
28.
Add any remarks that pertain to any item or

calculation above. Indicate any items or
hazards which require consideration by
operations, inspection or maintenance
personnel.
15

Miscellaneous Information (Entries 29-35)

29.
District and location.
30.
Plant number.
31.
Follow the usual procedure to obtain drawing

numbers.
32.
Include BI and JO under which the equipment

was installed.
33.
Complete this section showing date and name

of originator.
34.
Engineering concurrence as indicated in

Section 4 of this standard plus project manager
or plant manager's approval, as required.
35.
Signature of Facility Engineering Division head.
16

FORM 2821
FIGURE 1
17

WORK AID 2:
PROCEDURES FOR DETERMINING THE INFORMATION TO

COMPLETE A SAFETY INSTRUCTION SHEET FOR CROSSCOUNTRY PIPELINES
Work Aid 2A:
Saudi Aramco Form 5645-1

Use the following procedure in conjunction with Figure 2
complete Safety Instruction Sheet, Form 5645-1, for
pipelines. The identification numbers that are shown in
the following procedure correspond to those shown in
Figure 2. Reference SAES-A-005, Safety Instruction
Sheet, for additional information. Note that by the time it
is necessary to complete Form 5645-1, engineering has
been completed, all of the required information is readily
available, and no new calculations or selections are
needed.
Pipeline Identification (Entries 1-12)

1.
Give the official designation of the pipeline,

e.g., "Qatif-Ras Tanura Pipeline Number 6"
(QRT-6) and indicate the fluid that is being
handled, such as "stabilized Arabian Light
Crude," "fuel gas," or "water."
2.
Show the name of the pipeline origin, such as

"Qatif Junction."
3.
Show the name of the pipeline termination

point, such as "Ras Tanura."
4.
Indicate the type of fluid that is being handled,

such as Arab Light.
5.
Show the name of the valve operating diagram

of this line, such as "NACRUDE." If not
available, give the P & ID Drawing Number.
6.
Indicate the year in which the line was built.
18

7.
Give the Kilometer Number where the pipeline

begins.
8.
Give the Kilometer Number of the pipeline

where this particular sheet begins. A pipeline
will typically require several Forms 5645-1 to
cover its entire length. This entry defines
where this particular sheet starts.
9.
Show the number of sheets which cover all

major segments of the pipeline to be covered
by Form 5645-1. This entry defines how many
sheets are used for the entire pipeline.
Pipeline Identification (Entries 1-12), Cont'd

10. & 11. Enter the number of the sheet(s) that cover
items which will be covered by Form 5645-2,
as identified above.
12.
Segments of the pipeline are to be numbered

sequentially, i.e., Sheet 1 will show Segments
1-5, Sheet 2 will show Segments 6-10, and so
on. A single pipeline will have multiple
segments.
Note that each segment shall have the same
diameter, wall thickness, material grade,
hydrostatic test pressure, MAOP, Area
Classification, and type of construction. If any
of these characteristics change, a new
Segment Number is to be used. Also, the
portion of the pipeline that is located between
any two major facilities (such as a scraper trap,
pump station, or a junction point) shall be
considered as a separate segment even if it
has the same characteristics as an adjacent
segment.
19


13.
Nominal or outside diameter.
14.
Nominal wall thickness, with fractions shown in

decimals.
15.
Show the grade of pipe material, such as API

5L, GR. X50. SAMSSs references are not
acceptable.
16.
Enter the starting kilometer location of the

segment.
17.
Enter the ending kilometer of the segment.
18.
Indicate the length of the segment, in feet, as

shown on the layout drawing. Since the actual
routing of the pipe will not necessarily be
straight between kilometer stations, the length
of the pipeline segment is not simply the
difference between the two kilometer markers.
19.
Indicate the length of the segment in

kilometers.
20


20.
Show the process of manufacture for the pipe

(see the mill inspection report).
Seamless (S).
Longitudinally (straight seam) welded submerged-arc (Electricfusion welded) by U-ing, O-ing, Expanding (UOE-EFW).
Longitudinally (straight seam) welded submerged-arc (Electricfusion welded) by Cage Forming (CF-EFW).
Longitudinally (straight seam) welded electric-resistancewelded

(UOE-ERW), (CF-ERW).
Special-welded, submerged-arc (Spiral-EFW).

21.
Indicate the Specified Minimum Yield Strength

in psi, as shown on the mill certificates, for
each item of the purchase order. For example,
41,000 psi.
22.
Indicate the flange rating per ASME/ANSI

B16.5. Selection of the flange rating was
23.
Show the type of construction for the pipeline

segment as follows:
24.
B:
Buried
AGR: Restrained Aboveground.
AGN: Nonrestrained Aboveground.
Include any remarks that are related to pipe

material, such as "X65 pipe in Segment 3 is
installed on an experimental basis to check
weldability".
21


25.
Calculate the internal pressure that is required

to develop a hoop stress that is equal to the
Design Factor (DF) multiplied by the Specified
Minimum Yield Strength (SMYS) of the pipe
based on the pipe outside diameter (OD) and
nominal wall thickness (Tn).
MAOP = (DF)(SMYS)(2Tn)/(OD)
If other factors are limiting (such as flange
rating), indicate the lower MAOP and annotate
accordingly. MAOP of a pipe section was
26.
Indicate the limiting factor of the MAOP, and

whether it is the pipewall thickness or any other
factor, such as flange rating.
27.
Show the Design Factor of the segment, such

as 0.5, 0.6, or 0.72. Design Factor was
28.
Show the maximum design temperature.
29.
Indicate minimum design tie-in temperatures

specified in the project specification or "scope
of work".
30.
Indicate the allowable bending stress, Sb, per

SAES-L-051 and SADP-L-051. Allowable
bending stress was discussed in MEX 101.07.
31.
Calculate the required minimum wall thickness

of the pipe, Tm, based on the segment MAOP
and the Design Factor, DF. The required
minimum wall thickness of the pipe was
Tm = (MAOP)(OD) / [2(DF)(SMYS)]
Note that Tm is the retirement wall thickness,
and shall not be less than the required wall
22

thickness for mechanical strength. Refer to

Saudi Aramco Inspection Procedure 01-AIP02-0, SAES-L-006, or to the piping specialist in
the Consulting Services Department for further
explanation.
32.
Show the actual hydrostatic test pressure of

the particular segment of pipeline that is
performed immediately after construction. The
test pressure must be calculated in accordance
with SAES-A-004, Pressure Testing. Test
pressure requirements were discussed in MEX
101.09.
Operating Limits (Entries 25-40), Cont'd

33.
Show the test date.
34.
Indicate the factor that limits the test pressure,

such as pipewall thickness, flange rating,
branch connection, etc.
Note that entries for revalidation hydrostatic
tests (entries 35-37) are to be completed when
the information is known. The Safety
Instruction Sheet (SIS) is to be updated after
every revalidation test by the responsible
Operations Engineering unit.
35.
Indicate the actual test pressure for the

revalidation test. The test pressure shall be in
accordance with SAES-A-004 and approved by
the responsible Saudi Aramco Engineering
unit.
36.
Show the test date.
37.
Indicate the factor that limits the test pressure.

Note that this does not necessarily have to be
the same item that limited the initial hydrotest
pressure. For example, the original hydrotest
pressure might have been limited by the
flanges. However, corrosion which may have
occurred in the pipe, itself, could make it the
23

limiting component for a revalidation test.

38.
Indicate the Maximum Allowable Operating

Pressure (MAOP) of the entire pipeline as if
one system, if applicable. This MAOP will be
dictated by the lowest of the MAOP's across
the entire pipeline, or the maximum pressure
that is achievable upstream due to, for
instance, well head or pump shutoff pressure.
If the pipeline does not have one MAOP for the
system, indicate this by "N/A" and give a clear
explanation in the remarks area, such as "the
line is telescoped."
39.
Show the limiting factor that dictates the

system MAOP.
40.
Include any pertinent remarks that will assist

operations, inspection or maintenance
personnel. Any safety hazards for the pipeline
or fluid that is transported should be
mentioned. If the pipeline is constructed such
that the pipe, flanges, valves, or fittings will not
withstand the shutoff pressure of the pump
plus the static head pressure when a
downstream valve is closed, then this hazard
must be clearly highlighted.
Indicate if surge protection system(s) have
been provided. Make reference to any special
operating instructions.
24


41.
Include the drawing numbers of schematic

layout, P & I diagram, process flow diagram,
hydrostatic test diagram, and hydraulic profile
drawing.
42.
District and/or location and the official pipeline

name, as in Item #1.
43.
Show the Plant No.
44.
Follow the usual procedure to obtain a drawing

number.
45.
Include BI and JO under which the pipeline

was installed.
46.
Complete this section showing the date

prepared and the name of the originator.
47.

Section 4 plus Project Manager or Plant
Manager's approval, as required.
48.
Signature of Facility Engineering Division head.
25

FORM 5645-1
FIGURE 2
26

Work Aid 2B - Saudi Aramco Form 5645-2

Use the following procedure in conjunction with Figure 3
complete Safety Instruction Sheet, Form 5645-2, for
pipeline tie-in piping, scraper traps and their
appurtenances, jumpovers, as well as flanges, fittings,
any special components, road crossings, sun-pressure
relief valves, flowlines, trunklines, testlines, and
submarine pipelines. The identification numbers that are
shown in the following procedure correspond to those
shown in Figure 3. Reference SAES-A-005, Safety
Instruction Sheet, for additional information. Note that by
the time it is necessary to complete Form 5645-2,
engineering has been completed, all the required
information is readily available, and no new calculations
or selections are needed.
Pipeline Identification (Entries 1-9)
1.-6.
Same as corresponding Key Numbers 1-6 on

Form 5645-1.
7.
Provide adequate information to clearly identify

the equipment; for example, scraper trap, block
valve MOV-123, etc.
8.
Show the location of the equipment by name

and kilometer, such as Qatif Junction, km. 0.0.
In the case of flowlines, testlines, or trunklines,
show the GOSP name at which these lines
terminate.
9.
This section number corresponds to a

numbering system that is adopted in the
pipeline data book. Therefore, this information
must be coordinated with the proponent.
27


10.
Show the nominal or outside pipe diameter.

List each kind (one diameter, wall thickness
and steel grade) of pipe or fitting once in
separate columns.
11.
Show the nominal wall thickness of pipe,

fractions in decimals.
12.
Show the material, such as carbon steel, alloy,

etc.
13.
Indicate the process of manufacture for the

pipe, such as seamless (S) or EFW, ERW, or
spiral.
14.
Show the pipe material specification and grade,

such as API 5L, Gr. B. SAMSSs references
are not acceptable.

15.
Show the nominal size of flanges and fittings.
16.
Enter the rating per ASME/ANSI B16.5 for

flanges and valves. Selection of the flange
rating was discussed in MEX 101.04.
17.
Enter the type of flange face, such as raised

face (RF) or ring joint (RTJ). Flange facing
was discussed in MEX 101.04.
18.
Enter whether carbon steel or alloy is used for

flanges or fittings.
19.
Specify the ASTM or other specification and

grade of the material used for flanges or
fittings.
20.
List any special piping components that are not

otherwise covered, and include any other
pertinent remarks.
28


21.
Calculate the Maximum Allowable Operating

Pressure (MAOP) in accordance with the
applicable code, as limited by flanges or by the
nominal pipewall thickness, for materials that
are listed under Key Numbers 10 through 20.
MAOP was discussed in MEX 101.03 and MEX
101.04 for pipe and flanges, respectively.
22.
Show the item that is limiting the MAOP in Key

Number 21.
23.
Show the Design Factor, and give the basis of

the Design Factor in the remarks area in Key
Number 37. The Design Factor was discussed
in MEX 101.03.
24.
Show the design temperature.
25.
Show the actual hydrostatic test pressure of

this particular equipment item that was
performed immediately after construction. The
test pressure must be calculated in accordance
with SAES-A-004, Pressure Testing. Test
pressure requirements were discussed in MEX
101.09. The test pressure of this equipment
item must be equal to or greater than the test
pressure in Key Number 32, Form 5645-1, for
the pipeline segment to which this equipment is
connected.
26.
Show the test date.

27.
Indicate the item (pipeline segment, flange or

special fitting) which limits the test pressure.
Note that entries for revalidation of hydrostatic
tests (entries 28-30) are to be completed when
the information is known. The Safety
Instruction Sheet (SIS) is to be updated after
every revalidation test by the responsible
29

Operations Engineering unit.

28.
Indicate the actual test pressure for the

revalidation test, which must be in accordance
with SAES-A-004 and approved by the
responsible Saudi Aramco Operations
Engineering unit. The test pressure of this
equipment must be equal to or greater than the
test pressure in Key Number 35, on Form
5645-1, for the segment to which this
equipment is connected.
29.
Show the test date.
30.
Indicate the factor that limits the test pressure.

Note that this does not necessarily have to be
the same item that limited the initial hydrotest
pressure. For example, the original hydrotest
pressure might have been limited by the
flanges. However, corrosion which may have
occurred in the pipe, itself, could make it the
limiting component for a revalidation test.
31.
Indicate the Maximum Allowable Operating

Pressure (MAOP) of the entire pipeline as if
one system. This MAOP is the same as that in
Key Number 38 on Form 5645-1.
In case of flowlines, testlines, or trunklines,
refer to SADP-L-022 for further information.
32.
Show the limiting item for the system MAOP.

In the case where a Saudi Aramco standard
governs, indicate which standard it is and its
date, such as SADP-L-022, 30 August 1985.
33.
Show the set pressure of the safety valve, sunpressure relief valve, pressure switch, or other
safety device if one is included, and if it is
required for routine operation. Confirm this
information with the P & ID.
34.
Enter the nominal size or outside diameter.
30


35.
Calculate Tm based on the system MAOP that

is shown in Key Number 31. If not applicable,
use the MAOP in Key Number 21.
Note that Tm is the retirement wall thickness,
and shall not be less than the required wall
thickness for mechanical strength. Refer to
Saudi Aramco Inspection Procedures 01-AIP02-0, SAES-L-006, or to the piping specialist in
the Consulting Services Department, for further
explanation.
36.
Calculate the corrosion allowance (Tca) which

equals the nominal wall thickness of the pipe
minus Tm that is shown in Key Number 35.
Note that the corrosion allowance, Tca, is the
remaining pipewall thickness that is above the
required Tm. This is not a required corrosion
allowance. If a corrosion allowance is required,
it must be stated (including the referenced
standard) in the remarks area under Key
Number 37.
37.
Include any special remarks regarding safety

hazards in connection with items on the subject
sheet. See the remarks for the main line pipe,
Form 5645-1, Key Number 40.

38.
Indicate specific drawings for the manifolds,

crossovers, branches, scraper traps, road
crossings, and any items that are covered by
this sheet.
39.
Show the district, area or location, and the

official pipeline, or the equipment name, as
shown in Key Number 1.
40.
Enter the plant number.
31

41.
Follow the usual procedure to obtain a drawing

number.
42.
Include the BI and JO under which the

pipeline/equipment was installed or revised.
43.
Complete this section showing the date

prepared and name of the originator.
44.

Section 4, plus Project Manager or Plant
Manager's approval, as required.
45.
Signature of the Facility Engineering Division

head.
32

FORM 5645-2
FIGURE 3
33

GLOSSARY
AGN
Nonrestrained Aboveground
AGR
Restrained Aboveground
CF
Cage Forming
EFW
Electric-Fusion Welded
FF
Flat-Face Flange
NPS
Nominal Pipe Size
RF
Raised-Face Flange
RTJ
Ring-Joint Flange
Saudi Aramco
Form 2821
A Safety Instruction Sheet for Plant Piping
Saudi Aramco
Form 5645-1
A Safety Instruction Sheet for Cross-Country

Pipelines
Saudi Aramco
test Form 5645-2
and
A Safety Instruction Sheet for flowlines, trunk lines,

lines, submarine pipelines, tie-in piping, scraper traps
their appurtenances, and special components.
SMYS
Specified Minimum Yield Strength
UOE
U-ing, O-ing, Expanding
34

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