Saep 365 PDF

Engineering Procedure
SAEP-365 26 September 2016

Pump Spare Parts Reverse Engineering
Document Responsibility: Pumps, Seals, and Mixers Standards Committee
Contents
1 Scope.............................................................. 2
2 Conflicts and Deviations ................................. 2
3 Applicable Documents .................................... 2
4 Definitions and Acronyms ............................... 3
5 Responsibilities ............................................... 4
6 General Instructions ........................................ 5
7 Applicable 9COM Listing................................. 6
8 Purchase Order Instructions
and Specifications ................................... 7
9 Manufacturing Facility
Assessment Procedure.......................... 11
Revision Summary .............................................. 13
Appendix A - Re-Engineering Facility

Pre-Visit Survey Form............................ 14
Appendix B - Re-Engineering Facility
Auditing Aid ........................................... 16
Appendix C - Technical Capabilities
Audit Report Sample ............................. 19
Appendix D - Pump Spare Parts
Technical Specification Guideline .......... 20
Previous Issue: 6 September 2011 Next Planned Update: 26 September 2019

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Contact: Ghamdi, Abdullah A. (ghamaa3g) on +966-13-8809507
©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Pumps, Seals, and Mixers Standards Committee SAEP-365
Issue Date: 26 September 2016
Next Planned Update: 26 September 2019 Pump Spare Parts Reverse Engineering
1 Scope
1.1 This Saudi Aramco Engineering Procedure (SAEP) establishes the methodology
for obtaining reverse engineered pump spare parts from an approved spare parts
manufacturer. It specifies the minimum requirements and quality checks that
need to be included in the purchase order (PO). This procedure also identifies
the responsibilities of the various Saudi Aramco involved departments. Castings
for fire water pumps shall be approved by Fire Protection Department / Fire
Operations Technical Support Group.
1.2 This SAEP also establishes guidelines for surveying and assessing the technical
capabilities and Quality Management System effectiveness of new or existing
reverse engineering pump spare parts manufacturing facilities being considered
for addition to the Saudi Aramco approved manufacturers.
1.3 Additional requirements may be included in Scopes of Work, Drawings, or other

Instructions or Specifications pertaining to the PO.
1.4 Reverse engineering shall be considered only for non- patented designs or for
patented designs for which the patent covering the design has expired. Saudi
Aramco will not indemnify or defend any spare parts manufacturer against patent
infringement to whom a PO is issued hereunder. If there is any concern regarding
issues involving patents, the Law Department should immediately be consulted.
1.5 Reverse engineering shall not be used unless one of the conditions in Section 6.1
is met.
1.6 Any party involved in preparing the PO and subsequent party to whom work is
awarded shall not use or have access to OEM drawings.
2 Conflicts and Deviations
2.1 Conflicts between this Engineering Procedure and any other Saudi Aramco
Standards shall be resolved by the Consulting Services Department in writing.
2.2 Approval for deviating from the requirements given in this SAEP shall be
obtained by following the waiver instructions of SAEP-302.
3 Applicable Documents
Unless stated otherwise, all Standards, Specifications, and Codes referenced in this
procedure shall be of the latest issue (including revisions, addenda, and supplements)
and are considered a part of this procedure.
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3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-1142 Qualification of Non-Saudi Aramco NDT Personnel
Saudi Aramco Inspection Requirements

175-791100 Re-Engineered Pump Parts made by Machining or
Welding
175-791200 Re-Engineered Pump Cast Parts Other than
Impellers
175-791300 Re-Engineered Pump Impellers
3.2 Industry Codes and Standards
American Society of Mechanical Engineers

ASME SEC VIII D1 Rules for Construction of Pressure Vessels
ASME SEC IX Qualification Standard for Welding and Brazing
Procedures, Welders, Brazers, and Welding and
Brazing Operators
International Standards Organization

ISO 8062-3:2007 General Dimensional and Geometrical Tolerances
and Machining Allowances for Castings
ISO 9000 Quality Management Systems - Fundamentals and
Vocabulary
ISO 9001 Quality Management Systems Requirements
Manufacturers Standardization Society

MSS-SP-55 Quality Standard for Steel Castings for Valves,
Flanges and Fittings and Other Piping
Components - Visual Method for Evaluation of
Surface Irregularities
4 Definitions and Acronyms
9COM: Commodity Number.

Approved Manufacture: SAP approved spare parts manufacturer other than the OEM.
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CR&OU: Contracted Repair & Operation Unit

CSD: Consulting Services Department Pump Specialist/Engineer
ID: Inspection Department
MSSD: Mechanical Services Shop Department
NDE: None Destructive Examination
NDT: None Destructive Testing (same as NDE)
OEM: Original Equipment Manufacturer
ID&SSD: Industrial Dev & Strategic Supply Department
PMI: Positive Material Identification
PO: Purchase Order
VID: Vendor Inspection Division
Quality Plan: Document specifying which procedures and associated resources shall
be applied by whom and when to a specific project, product, process or contract.
[ISO 9000]
Quality System: Organizational structure, procedures, processes and resources needed

to implement quality management. [ISO 9000]
Reverse Engineering: The process by which a mechanical component can be modeled

by evaluating its mechanical and performance characteristics and measuring its physical
dimension in order to produce a duplicate or an enhanced version of the component.
SAEP: Saudi Aramco Engineering Procedure
SAP: Saudi Aramco corporate database that includes various types of material masters,
i.e., 9COM, 9CAT, etc.
SCC: Standards Committee Chairman; Pumps, Seals and Mixers
5 Responsibilities
5.1 CSD shall be the technical approval authority for manufacturers not listed as
approved manufacturer in Saudi Aramco SAP System.
5.2 ID is responsible for reviewing and approving the manufacturer Quality Plan
and inspection and test plans. ID is also responsible for the quality management
system approval of the reverse engineering vendors.
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5.3 It is the responsibility of ID&SSD to register new casting and fabrication

facilities and to initiate and coordinate the SAP Approval Workflow.
5.4 MSSD, CSD, and other surveying organizations are responsible for reviewing
the technical capabilities of the manufacturer.
5.5 It is the responsibility of VID inspector or proponent to witness and verify the
material tests and dimensional checks for impellers and casing parts as specified
in the inspection forms. For pump spare parts other than impeller and casing
parts, it is the responsibility of the spare part receiving organization, such as
MSSD or plant maintenance department, to conduct in-house Positive Material
Identification (PMI) and dimensional checks for verifying compliance to the PO
specifications.
5.6 Saudi Aramco repair facility shall be responsible to supply the required spare
part dimensions by providing a sample or non OEM drawings and include all
required critical dimensions (such as runout and concentricity) in the PO.
The original equipment manufacturer (OEM) drawings shall not be included in
the P.O. nor shall be used to generate any drawings.
5.7 For pumps repaired by a non-Saudi Aramco repair facility, it is the

responsibility of the Saudi Aramco organization requesting the repair, such as
MSSD or field maintenance department, to ensure that the requirements of this
procedure are adhered to when the repair facility is going to utilize a reverse
engineered spare part.
5.8 Non-destructive Testing Unit of the Operations Inspection Division shall be

responsible for approving the NDT process, NDT procedures, NDT qualifications,
NDT written practice, etc.
6 General Instructions
6.1 Reverse engineering may only be considered when:

i) The OEM no longer exists.
ii) The OEM no longer produces the product.
iii) The product performance and features need improvement.
iv) The OEM is quoting an inflated price. In this case, concurrence must be
obtained from ID&SSD / Sourcing Management Unit in order to proceed
with the purchase order.
v) The OEM is quoting an unacceptable delivery time that cannot be
improved with application of commercially reasonable premium payments.
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6.2 Reverse engineering shall be considered only for non-patented designs or for
patented designs for which the patent covering the design has expired. Saudi
Aramco will not indemnify or defend any spare parts manufacturer against
patent infringement to whom a PO is issued hereunder. If there is any concern
regarding issues involving patents, the Law Department should immediately be
consulted.
6.3 Procurement of spare parts made by a manufacturer not listed as approved spare
part manufacturer in Saudi Aramco SAP system is not allowed without
approval. Approval may be granted on a case-by-case basis limited to a specific
PO in accordance with the Saudi Aramco one time approval procedure.
Such business decision shall be established jointly by the party requesting the
approval and the approving authority (CSD and ID) in the best interest of Saudi
Aramco, technically and commercially. Requests for approval of an unapproved
manufacturer must be supported by documentation identifying how this
manufacturer would better serve Saudi Aramco over the approved
manufacturers.
6.4 Approved spare parts manufacturers may be considered as an alternative

supplier in addition to the OEM for a specific equipment spare part, if the
manufacturer provided spare parts to Saudi Aramco that had served for more
than two years with satisfactory operation.
6.5 Any modification to an existing spare part design shall be approved by the SCC.
6.6 If a sample or a Saudi Aramco drawing is not available for reverse engineering
of impellers and casing parts, approved spare part manufacturers may be
allowed to design a new spare part to meet the pump requirements. In such
case, CSD shall be consulted to determine the proper required testing to verify
the pump capability such as factory testing or field testing.
7 Applicable 9COM Listing
7.1 9COM number 6000012812: Re-Engineered Pump Components made by Casting.
The inspection and testing requirements for this 9COM shall be in accordance
with the PO instructions and inspection form 175-791300 for impellers and
inspection form 175-791200 for casing parts. This 9COM includes the
following pressure retaining and non-pressure retaining pump spare parts made
by casting: impellers, casings, bearing housings, diffusers, discharge bowls,
suction bell mouths, and stuffing boxes.
Note: The spare parts inspection requirement may be waived for pumps in non-critical
applications if approved by the SCC.
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7.2 9COM number 6000011675: Re-Engineered Pump Parts made by Machining or

Welding.
The inspection and testing requirements for this 9COM shall be in accordance
with the PO instructions and inspection form 175-791100. This 9COM includes
but not limited to the following pump spare parts: shafts, sleeves, bushings,
wear rings, column pipes, vertical pump head, and coupling hubs.
8 Purchase Order Instructions and Specifications
As there are no specific standards addressing spare parts manufacturing, it is the

responsibility of Saudi Aramco repair facility requesting the part to include all
applicable technical specification in the PO specification. To assist in this manner, the
below instructions are given in addition to the technical specification guideline in
Appendix D.
8.1 Saudi Aramco repair facility should specify the spare part exact material in the
PO. If there is a need for a material upgrade, they may contact CSD for
recommended upgrade material.
8.2 The PO shall specify all the casting and machining tolerances. For machining,
special focus shall be given to clearance and interference fits which shall be
based on OEM settings, API limits or MSSD repair procedures. For casting,
special focus shall be given to vane thickness, inlet and outlet vane angels, and
vane profile for impellers, diffusers, and volutes.
8.3 Saudi Aramco repair facility shall include a detailed drawing in the PO to show
the locations and values of the required critical dimensions such as runout and
concentricity. Original OEM drawing shall not be included in the PO nor shall
original OEM drawings be used to generate any drawings. Saudi Aramco will
not indemnify or defend any spare parts manufacturer against patent or
copyright infringement to whom a PO is issued hereunder.
For reverse engineered parts where a detailed drawing is not available, a sample
of the part shall be given to the manufacturer to develop his own drawing.
Unless approved by the SCC, the manufacturer shall develop a detailed drawing
for cast parts using 3D measurement device if one or more of the following
criteria is met:
Impellers Pressure Retaining Casing Parts

Rotating speed above 3,600 rpm Pressure casings for all between bearing pumps
Diameters larger than 15 in.
Vertical pump bowls with O.D. above 20 in.
Power (per stage) exceeds 300 HP
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For parts other than the above, the manufacturer is free to choose the appropriate
measurement method including hand measurement to produce a 2-D drawing
which shall be sent for purchaser review. Hand tools can be used to make the
pattern. Metal loss of the supplied sample and the casting shrinkage shall be
taken into account.
When a 3D measurement is required, the manufacturer shall generate the 3D

model of the part taking into account any existing damage in the original sample
such as thinning due to erosion and corrosion. This 3D model shall be sent for
purchaser review. All critical dimensions and tolerances shall be clearly
specified in this drawing in order to be verified by the purchaser. The finalized
3D model shall be used to develop the casting pattern, using an automated 3D
machining device, taking into account all casting process effects such as
shrinkage. A 3D measurement shall be conducted for the final product and shall
be compared with the original 3D model to ensure meeting the PO tolerances.
For components requiring 3D measurements, the use of hand tools to develop
impeller and pressure casing pattern is not allowed unless approved by the SCC
and proponent.
8.4 Radiographic examination shall be conducted on cast impellers if the peripheral

velocity at rated speed is 75 m/s (250 ft/s) or higher. Radiographs shall be made
after machining and shall cover impeller shrouds over the outer 75 mm (3 in) of
the radius. In addition, radiographs shall also be taken through the impeller,
thus showing the intersection of the vanes and shrouds.
Impellers shall be subjected to a fluorescent magnetic particle examination

(ferromagnetic material) or a liquid penetrant examination (non-ferromagnetic
material) if the peripheral velocity of the impeller at rated speed is 45 m/s
(150 ft/s) or higher. All visible surfaces of the finished impeller (prior to wear
ring installation) shall be examined and shall be in agreement with the criteria
set forth in the ASME SEC VIII D1, Appendices 6 and 8.
Deviation from this requirement requires SCC approval.
8.5 Hardness testing shall be required in the PO for parts subjected to sour service or
if the material needs to have a specific hardness such as wear rings.
8.6 NDT requirements specified in the inspection forms represent the minimum
requirements. The Saudi Aramco repair facility may specify additional NDT
testing in the purchase order.
Note: The repair facility may consult with Saudi Aramco Operations Inspection
Department NDE Unit to determine the feasibility of additional NDE testing.
8.7 The Saudi Aramco repair organization such as MSSD or field maintenance
department shall contact CSD to determine the additional requirements that need
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to be included in the PO for manufacturing cast spare parts for pumps that meet
one or more of the following criteria:
i) Pump speed is more than 3,600 rpm.
ii) Pump driver is more than 1,000 HP.
iii) Pump fluid specific gravity is less than 0.7.
iv) Pump liquid temperature is more than 250°F or less than 32°F.
v) Pump maximum allowable working pressure more than 900 psig.
vi) Pump in sour service with H2S concentration of more than 1,000 ppm.
8.8 All weld repairs and post weld heat treatment shall conform to the original
material specification of the casting. All welding procedure specifications,
performance qualification records, and weld map documents must be available
for the purchaser inspector review upon his request.
Weld repairs of pressure containing castings, including impellers, shall be

considered major if any of the following conditions apply:
a) Castings leak during hydrostatic testing
b) The depth of the repair cavity prepared for welding exceeds 20% of the wall
thickness or 25 mm (1 in), whichever is smaller
c) The surface area of the repair cavity exceeds 65 cm² (10 in²).
All major weld repair procedures, including the welding procedure

specifications (WPS), with supporting documentation shall be prepared and
submitted to the Buyer Representative for review and approval by the SCC prior
to any repairs being conducted.
Welders shall be qualified in accordance with the requirements of ASME SEC IX.
All major repairs shall be documented. The documentation shall include the
following:
a) Extent of the repair
b) Location
c) Size
d) The welding procedure specification
e) Detailed photographs of the defect:
1) Prior to any preparatory work
2) After preparation but prior to the actual repair.
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If the location of the defect cannot be clearly defined by photographic means,

the location shall be indicated on a sketch or drawing of the affected component.
The Purchaser may require additional non-destructive examinations to verify the

acceptability of the repair. Such additional requirements shall then be subject to
mutual agreement between the Purchaser and the Vendor.
8.9 Surfaces of castings shall be cleaned by sandblasting, shot blasting, chemical

cleaning or other standard method to meet the visual requirements of MSS-SP-55.
Mould-parting fins and remains of gates and risers shall be chipped, filed or
ground flush.
8.10 Magnetic-particle or liquid-penetrant examination is required for auxiliary

connection welds. Radiographic examination is required for the welded areas of
the suction and discharge nozzles and any casing welds. Radiographic
examination may be substituted by ultrasonic or liquid penetrant examination if
approved by the Standards Committee Chairman; Pumps, Seals, and Mixers.
8.11 For pressure retaining castings, magnetic particle examination shall be

conducted on all accessible surfaces of ferromagnetic castings except machined
gasket surfaces. Liquid penetrant examination shall be conducted on all
machined gasket surfaces of all materials and on all accessible surfaces of non-
ferromagnetic castings.
8.12 For pressure retaining castings, radiographic examinations shall be performed

for the following services:
a) Services where the maximum discharge pressure exceeds 900 psig
(integrally geared pumps are excluded);
b) Services where the maximum temperature exceeds 260°C (500°F);
c) Boiler feed water services where the maximum operating temperature
exceeds 149°C (300°F);
d) Services where the minimum operating temperature is below minus 29°C
(minus 20°F);
e) Autoignition services;
f) Sour services with H2S concentration above 1,000 ppm;
g) Flashing hydrocarbon services where the maximum allowable working
pressure exceeds 500 psig.
Radiographic examinations shall be performed on the pressure retaining castings

at following areas:
i- Junctions of risers, gates and feeders;
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ii- Transition between casing and both suction and discharge nozzles;
iii- Transition between casing and volute flanges;
Iv- Transition between casing and feet;
v- Junction where the casing meets the seal housing.
8.13 Hydrostatic test shall be conducted for all pressure retaining parts and shall be
witnessed by VID inspector or proponent. The test shall be performed at
1.5 times the maximum allowable pressure at ambient temperature and for a
minimum of 30 minutes. In case of test failure, the vendor shall submit his
repair procedure to Saudi Aramco for review and approval.
8.14 Impellers, balancing drums, and similar major rotating components shall be
dynamically balanced to ISO 1940-1 grade G2.5. The mass of the arbor used for
balancing shall not exceed the mass of the component being balanced.
9 Manufacturing Facility Assessment Procedure
9.1 Facility Evaluation Phases
This section provides general guidelines to be considered by Saudi Aramco

auditors conducting facility assessment visits. Typical manufacturing facility
survey consists of both technical and quality system evaluations and can be
implemented in two main phases; pre-visit phase and facility visit phase.
The below two subsections for the two phases contain the minimum information
needed to complete the assessment. It shall be completed to the full extent
possible; additional engineering judgment shall also be part of the evaluation, as
occasionally it may not be possible to complete all the inquiry fields.
9.1.1 Pre-Visit Phase
This phase addresses the data that need to be collected before the visit
and the items that need to be prepared prior to the plant visit. The below
list covers some of the main items in this pre-visit phase:
a) Obtain a copy of the factory invitation letter.
b) Request a list of sub-suppliers, their locations to visit if needed.
c) Ask for experience list.
d) Obtain an organizational chart for the specified manufacturing plant
to show all available facilities.
e) Obtain a copy of the ISO 9001 Quality Manual and six mandatory
procedures.
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f) Obtain a copy of the ISO 9001 Certificate if the manufacturer is

certified.
g) If the manufacturer has an engineering department, then obtain a
copy of the department organization chart and determine the number
of engineers and their disciplines. If not, determine if there is any
outside design consultants used and get their information.
h) Request the manufacturer to fill in the pre-visit survey form shown
in Appendix A.
i) Request a list of in-house and outsourced manufacturing activities

and available in-house design software and tools.
The assessment team shall meet and review the provided information
from the manufacturer and agree on the individuals responsibilities.
The lead auditor shall inform the organization of the audit schedule at
least seven days prior to the assessment.
9.1.2 Facility Visit Phase
This phase addresses the items to be covered during the plant visit.
Appendix B addresses the visit plan and some of the main checks needed
to complete the assessment.
The team should obtain copies of all needed procedures and qualification
records for review by the responsible Saudi Aramco organizations such
as Non-destructive Testing Unit for approving the NDT process, NDT
procedures, NDT qualifications, and NDT written practice.
9.2 Quality Requirements and Evaluation
9.2.1 ISO 9001 certification is not mandatory. However, the spare parts
manufacturer shall operate a Quality System in accordance with
ISO 9001 which will be verified during the survey by Saudi Aramco ID
representative.
9.2.2 Qualification of none Saudi Aramco Non-Destructive Testing (NDT)

personnel should be as per SAEP-1142. NDT national and international
Certification Programs may be accepted if approved by Non-destructive
Testing Unit of Saudi Aramco Inspection Department.
9.3 Reporting
Upon completion of the plant assessment visit, a technical assessment report

should be generated to compile the assessment findings and reflect the
conclusions and recommendations. The report should be addressed to the VID
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and copies may be distributed as needed to: MSSD, CSD, and other related
departments. A copy of this report should be attached in the SAP workflow by
VID to be used for later reviews. The report must include as a minimum the
following items (Appendix C shows a sample report format):
i) Introduction that provides background description of the plant being
surveyed, plant products, certifications, and surveying organizations.
ii) Summary of the survey key highlights including: activities done during the
visit, plant capabilities, equipment, manufacturing processes, inspection
and testing capabilities, production limitations, etc.
iii) Recommendations, concerns and required corrective actions for approving
the manufacturer.
iv) Attachment of the completed facility survey forms shown in Appendices A
and B.
The technical survey team must issue their technical assessment report within
five working days of completing the survey and send it to the SCC for review.
VID auditors will complete the quality system auditing report which will be
added in the SAP workflow
Revision Summary
26 September 2016 Major revision to update some requirements to be aligned with the local facilities
capabilities, to include firewater pumps in re-engineering, and to update the inspection
requirements (175 forms).
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Appendix A - Re-Engineering Facility Pre-Visit Survey Form
1.0 FACILITY INFORMATION

Company Name:
Address: Website ( if available):
City: Telephone:
Country: Fax:
Contact person: e-mail:
Vendor partner company/group name:
Address:
Company start up name & date:
2.0 MAJOR CUSTOMERS (list all major customers and supplied products)
3.0 PUMPS SPARE PARTS PRODUCT INFORMATION (Tick one Box)

Experienced in manufacturing the part. Capable of making the part but did not manufacture it before. Not Capable of manufacturing the part.
Experienced Capable Not Capable Experienced Capable Not Capable
Impellers Column pipes
Casings Stuffing boxes
Diffusers Bearing housings
Shafts Discharge bowls
Sleeves Coupling hubs
Bushings Suction bell mouths
Wear rings
Others Pump Spare Parts (Please specify):
3.2 List all company license, certification and standards and codes used:
3.3 Type of re-engineering measurement tools and methods. Manual Automated

(Please specify):
3.4 What is your production limitation?
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3.5 Do you have long term filling system for the part drawings, QA tests, etc. ? YES NO
3.6 Do you have a material traceability system? YES NO
3.7 List all the main casting materials:
3.8 List all used casting methods:
4.0 MANPOWER
Total Number of Employees: Number of Engineers:
Number of QA/QC Personnel: Saudization %:
Number of qualified welders: Total Number of qualified NDE personnel:
5.0 PROCESS (Tick Box if applicable)
Welding Processes: SMAW GTAW FCAW SAW PLASMA

NDT Processes: PT MT UT RT
Painting/ Coating YES NO N/A Surface Blasting YES NO N/A
Heat Treatment YES NO N/A Mechanical Testing Lab YES NO N/A
Hydro Test YES NO N/A Metallurgical Lab YES NO N/A
Calibration Lab YES NO N/A Foundry YES NO N/A
Others (Please specify):
6.0 SUB-SUPPLIERS and SUB-CONTRACTORS

6.1. List the major Sub-Suppliers of raw materials/Sub-Components
Sub-Supplier Name Raw Material/Sub-Components
6.2. List the major Sub-Contractors of work/service

Sub-Contractor Name Service
Completed by:
Name: Position: Signature: Date:
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Appendix B - Re-Engineering Facility Auditing Aid
Visit Plan:
 Brief presentation
 Plant tour
 Discussions
Items to be covered in the presentation:

 Company history
 Organization chart
 Quality management system and certifications
 Company license, certification, standards, and codes used
 Manufacturing process
 Production facilities and equipment
 Material standards and traceability
 Major customers and success stories
 Experience list if available
 In-house and outsourced manufacturing activities
 Available in-house design software and tools
 Safety
 Casting technique and capability/limitations if applicable
 Automated measurement tools for casting part if applicable
 Casting material grades if applicable
 Machining/ fabrication/ balancing capability/limitations if applicable.
Items to be covered in the Discussions:
 Verifications and clarifications for the submitted data in the pre-visit phase such as the data
in the facility pre-visit survey form and the quality manual
 Quality management system in compliance with International Organization for Standardization
ISO 9001 which will be verified during the survey by Saudi Aramco ID representative
 The manufacturer should describe the overall Quality Management System employed on
the project and identify those processes, procedures, and other documents that ensure
effective operation and control of the processes including those of subcontractors.
 Discussion of any corrective actions required by the manufacturer.
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Re-Engineering Facility Check List:

No. Item To be Checked Yes No N/A Comments
Is the facility familiar with ISO (International Standard
1
Organization)?
Is the facility familiar with API (American Petroleum
2
Institute)?
Is the facility familiar with ASME (American Society
3 of Mechanical Engineers) and ASTM standards
(American Society for Testing and Materials)?
Is the facility familiar with SASO (Saudi Arabian
4
Standard Organization)?
Verify all company license, certification, standards,
5
and codes used.
6 Does the facility have a Quality System manual?
Are all the employees (including craftsmen) aware of
7
this Quality manual?
Is Quality System manual being practiced by all
8
employees (including craftsmen)?
9 Does the facility have a Quality Assurance manual?
Does the facility produce evidence of completing similar
10
request level of spare parts?
11 Is the facility size suitable for the intended work?
Does the facility own separate and environmentally
12 controlled serviceable and unserviceable spare parts and
raw material store area/shelter?
Is the facility equipped with necessary handling
13
equipment (overhead cranes, forklifts, etc.)?
Does the facility issue the required safety protective
14
tools, clothing, etc., to its employees?
Are the employees formally aware of potential
15 manufacturing hazards, e.g., hot materials, toxic fumes,
etc.?
Do the facility premises contain a chemical cleaning
15
facility?
State the Saudi percentage in the management
16
workforce?
17 State the Saudi percentage in the shop floor workforce?
18 Does the facility have automated measurement tools?
19 Does the facility have an adequate job tracking system?
Does the facility have welders and welding procedures?
Does the facility welders qualification and welding
procedures comply with international standards such as
20 ASME SEC IX
Are the certified welders’ certificates valid?
Does the facility have welder qualification records
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No. Item To be Checked Yes No N/A Comments

and is it updated?
Does the facility have post weld heat treatment
capabilities with certified procedures?
Does the facility have long term filling system for the
21
parts drawings, QA tests, etc.
Does the facility contain a Calibration shop?
Does the facility have a certified calibration work force
and procedures?
22
If yes, are their certificates valid?
Does the facility calibrate its measuring tools and
instruments utilizing a third party?
Does the facility contain Radiography testing (RT)
capabilities
Does the facility have a certified RT personnel and
procedures?
23 Does the facility contain NDT capabilities?
Does the facility have a certified NDT personnel and
procedures?
Does the facility contain a material analysis laboratory?
Does the facility have a certified material analysis
24
personnel and procedures and calibrated equipment?
Do facility premises contain Hydrotest Area?
Does the facility have mechanical testing capabilities for
hardness?
25
Is the facility equipped with certified testing workforce
and procedures?
Does the facility have Internal Coating capabilities
(e.g., Hard coating)?
26 Does the facility have a certified work force and
procedures for internal coating?
Does the facility have criteria for assessing in-service
27
(reject/accept) parts?
Do the above criteria (Item # 27) conform to Saudi
28
Aramco procedures and ISO 9001:2000?
29 Does the facility have machining capabilities?
Page 18 of 32
Appendix C - Technical Capabilities Audit Report Sample
Date
"Manufacturer Name" Technical
Capabilities Evaluation Report
INSPECTION DEPARTMENT
VENDOR INSPECTION DIVISION
On "date", representatives from CSD, MSSD… conducted a technical evaluation for

"manufacturer name" facility located in "facility location" to verify their capabilities for reverse
engineering pump spare that falls under 9COM number 6000012812 and/or 6000011675.
This report summarizes the finding and recommendation of this Evaluation.
i) Surveying Participants
Participant Name Department Email Address (@aramco.com)
ii) Manufacturing Facility Background

(Introduction and summary of plant history, certifications, and experiences)
iii) Manufacturer Capabilities and Limitations Summary
(Summary of the survey key highlights including: activities done during the visit, plant
capabilities, equipment, manufacturing processes, inspection equipment, production
limitations, etc.)
iv) Recommendations and Corrective Actions
(Recommendations, concerns and required correction actions for approving the
manufacturer if any, suggestions for manufacturer development, etc.)
Participant's initials
Attachments:
1- Re-Engineering Facility Pre-Visit Survey Form
2- Re-Engineering Facility Check List
cc: Supervisor, CSD/RED/REU with attachment

RED Pump Engineers with attachment
Other Participants with attachment
Page 19 of 32
Appendix D - Pump Spare Parts Technical Specification Guideline
Use the following guideline to generate the technical specification documents for the applicable
part (examples are included):
I- Technical Specification Sample for Impeller
1- Specify the original and new materials.
Original impeller material is ASTM A216 WCB.
New impeller material is ASTM A743 CF3M.
2- Specify the required quantity

Quantity: 3
3- Use the pump datasheet to specify pump parameters. Verify if any of the criteria in
paragraph 8.7 is met.
i- Pump speed = 3,600 rpm
ii- Pump driver HP Rating = 500 HP
iii- Pump fluid specific gravity = 0.8
iv- Pump liquid temperature = 115°F
v- Maximum allowable working pressure = 550 psig
Note: Since none of SAEP-365 paragraph 8.7 limits are exceeded, it is not required to
contact CSD to specify any additional testing.
4- Include the impeller main dimensions.

Approximate impeller diameter = 32 inch. Other approximate dimensions are shown in the
below picture.
Page 20 of 32
5- Specify the impeller weight

Approximate impeller weight = 200 Lb
6- Indicate the pump service

Service: Sweet Crude Oil (no H2S).
Note: If the service is sour (H2S is present), hardness test shall be conducted and shall
meet ISO 15156.
7- Include the following statement if any of the criteria in paragraph 8.3 is met:
Using the result of the 3D measurement, the manufacturer shall generate the 3D
model of the part which should account for any existing damage in the original
sample such as thinning due to erosion and corrosion. This 3D model shall be sent
for purchaser review. All critical dimensions and tolerances shall be clearly
specified in this drawing in order to be verified by the purchaser. The finalized 3D
model shall be used to develop the casting pattern using an automated 3D
machining device, taking into account all casting process effects such as shrinkage.
A 3D measurement shall be conducted for the final product and shall be compared
with the original 3D model to ensure meeting the PO tolerances. For components
requiring 3D measurements, the use of hand tools to develop impeller and pressure
casing pattern is not allowed unless approved by the SCC and proponent.
Note: Since the impeller diameter in the above example is more than 15 in, 3D scanning
of the provided sample impeller is required.
8- Include the following statement for Dimensional Tolerances:

The manufacturer shall ensure that the final product meets the below required
tolerances. Special focus shall be given to vane thickness, inlet and outlet vane
angels, vane profile and impeller inlet area. Unless otherwise specified, the below
tolerances shall be met:
I. Vane leading edge and trailing edge angels shall be within ±0.5 degree.
II. Unless otherwise specified in the drawing and agreed with purchaser, the
tolerances for the linear casting dimensions and wall thickness shall be per
ISO 8062-3:2007 grade DCTG 6 and the tolerances for the general
geometrical casing shall be per ISO 8062-3:2007 grade GCTG 5.
III. The tolerances for general machined surfaces shall not be more than
0.05 mm (0.002 inch) and the tolerances for general machined length shall
be ±1.0 mm. Critical clearance and interference fits, such as impeller bore
and wear ring outer diameter, shall be agreed upon by the manufacture and
purchaser during the development and finalizing of the impeller drawings.
Page 21 of 32
9- Attach Inspection Form 175-791300. The manufacturer shall meet all the inspection
and testing requirements specified in the technical specification and Inspection
Requirement Form 175-791300.
Note: Since none of SAEP-365 paragraph 8.7 limits are exceeded in this example, no
addition testing other than Inspection Requirement Form 175-791300 is required.
10- State that all subcontracted work, such as balancing, heat treatment and hard
coating, shall be done at an approved Saudi Aramco facility (contact
MSSD/CR&OU for the approved list). All applicable NDTs shall be done per
ASME BPVC, Section V. Machining of parts shall be done at a Saudi Aramco
approved facility under 9COM # 6000011675. The spare part manufacturer shall
refer to Saudi Aramco MSSD for list of approved facilities.
11- Wear rings shall be per Section III of Appendix D.
12- Chaplets shall not be used in impeller castings.
13- Casting surfaces shall be cleaned by sandblasting, shot blasting, chemical cleaning
or other standard method to meet the visual requirements of MSS-SP-55. Mould-
parting fins and remains of gates and risers shall be chipped, filed or ground flush.
14- Specify if Radiographic examination is required per paragraph 8.4.
Radiographic examination shall be conducted on the impeller since the peripheral velocity
at rated speed is 502 ft/s (3,600 / 60 x Π x 32” / 12).
15- Specify the required tests for all visible surfaces as per paragraph 8.4.
Since the impeller peripheral velocity (502 ft/s) is higher than 150 ft/s and since the impeller
material is non-ferromagnetic material, all visible surfaces of the finished impeller (prior to
wear ring installation) shall be examined by liquid penetrant and by shall be in agreement
with the criteria set forth in the ASME SEC VIII D1, Appendices 6 and 8.
16- Include paragraph 8.8 in the technical specification document:

All weld repairs and post weld heat treatment shall conform to the original material
specification of the casting. All welding procedure specifications, performance
qualification records, and weld map documents must be available for the purchaser
inspector review upon his request.
Weld repairs shall be considered major if any of the following conditions apply:
a) The depth of the repair cavity prepared for welding exceeds 20% of the wall
thickness or 25 mm (1 in), whichever is smaller.
b) The surface area of the repair cavity exceeds 65 cm² (10 in²).
All major weld repair procedures, including the welding procedure specifications
(WPS), with supporting documentation shall be prepared and submitted to the Buyer
Page 22 of 32
Representative for review and approval by the SCC prior to any repairs being
conducted.
All major repairs shall be documented. The documentation shall include the extent
of the repair, location, size, welding procedure specification, and detailed
photographs of the defect prior to any preparatory work and after preparation but
prior to the actual repair.
If the location of the defect cannot be clearly defined by photographic means, the
location shall be indicated on a sketch or drawing of the affected component.

17- Specify the balancing requirements per paragraph 8.14.
Page 23 of 32
II- Technical Specification Sample for Pump Casing

Original casing material is ASTM A216 WCB.
New casing material is ASTM A743 CF3M.
2- Determine the required quantity.

Quantity: 1
3- Include the casing dimensions.

Approximate dimensions are shown in the below pictures.
4- Use the pump datasheet to specify the pump parameters in paragraph 8.7.
Pump Parameter

Page 24 of 32
v- Maximum allowable working pressure = 750 psig.
Note: Since some of SAEP-365 paragraph 8.7 limits are exceeded, the person developing
the PO specification shall contact CSD to specify additional testing.
5- Specify the casing weight

Approximate casing weight = 2,000 Lb
6- Indicate the pump service and type

Service: NGL booster pump.
meet ISO 15156. Since this is not a sour application (no H2S), hardness test is not
required.
7- Include the following statement if any of the criteria in 8.3 is met:
Using the result of the 3D measurement, the manufacturer shall generate the 3D
model of the part which should account for any existing damage in the original
sample such as thinning due to erosion and corrosion. This 3D model shall be sent
for purchaser review. All critical dimensions and tolerances shall be clearly
specified in this drawing in order to be verified by the purchaser. The finalized 3D
model shall be used to develop the casting pattern, using an automated 3D
machining device, taking into account all casting process effects such as shrinkage.
A 3D measurement shall be conducted for the final product and shall be compared
with the original 3D model to ensure meeting the PO tolerances. For components
requiring 3D measurements, the use of hand tools to develop impeller and pressure
casing pattern is not allowed unless approved by the SCC and proponent.
Note: Since the pump is a between-bearing type, 3D scanning of the provided sample
casing is required. Drawing may be generated by manual measurement and
casting pattern may be developed using hand tools.

tolerances. Special focus shall be given to volute\diffuser wall thickness,
volute\diffuser leading edge angels, geometrical similarity for all volutes\diffusers
with correct centerline, and volutes\diffusers trailing edge angels. Unless otherwise
specified, the below tolerances shall be met:
I. Volutes\diffusers leading edge and trailing edge (when applicable) angels
shall be within ±0.5 degree.
II. Unless otherwise specified in the drawing and agreed with purchaser, the
tolerances for the linear casting dimensions and wall thickness shall be per
ISO 8062-3:2007 grade DCTG 6 and the tolerances for the general
geometrical casing shall be per ISO 8062-3:2007 grade GCTG 5.
Page 25 of 32
III. The tolerances for general machined surfaces shall not be more than 0.05 mm
(0.002 inch) and the tolerances for general machined length shall be ±1.0 mm.
Critical clearance and interference fits, such as casing wear ring outer diameter,
internal centering\alignments of all casing machined surfaces and casing split
line flatness, shall be agreed upon by the manufacture and purchaser during the
development and finalizing of the casing drawings.
and testing requirements specified in this PO technical specification and Inspection
Requirement Form175-791200.
Note: Since some of SAEP-365 paragraph 8.7 limits are exceeded, the person developing
the PO specification shall contact CSD to specify additional testing.
10- Include paragraph 8.13: Hydrostatic test shall be conducted for all pressure retaining
parts and shall be witnessed by VID inspector. The test shall be performed at
1.5 times the maximum allowable pressure at ambient temperature and for a
minimum of 30 minutes. In case of test failure, the vendor shall submit his repair
procedure to Saudi Aramco for review and approval.
11- State that all subcontracted work, such as balancing, heat treatment and hard
coating, shall be done at an approved Saudi Aramco facility (contact
MSSD/CR&OU for the approved list). All applicable NDTs shall be done per
ASME BPVC, Section V. Machining of parts shall be done at a Saudi Aramco
approved facility under 9COM # 6000011675. The spare part manufacturer shall
refer to Saudi Aramco MSSD for list of approved facilities.
12- Include paragraph 8.10: Magnetic-particle or liquid-penetrant examination is
required for auxiliary connection welds. Radiographic examination is required for
the welded areas of the suction and discharge nozzles (if applicable) and any casing
welds. Radiographic examination may be substituted by ultrasonic examination, if
approved by the Standards Committee Chairman; Pumps, Seals, and Mixers.
13- Include the following requirements according to paragraph 8.12:
Radiographic examinations shall be performed on the pressure retaining castings at
following areas:
i. Junctions of risers, gates and feeders;
ii. Transition between casing and both suction and discharge nozzles;
iii. Transition between casing and volute flanges;
iv. Transition between casing and feet;
v. Junction where the casing meets the seal housing.
Note: Since some of SAEP-365 paragraph 8.12 limits are exceeded, the above
radiographic examinations requirements were added to the PO specification.
Page 26 of 32
14- Specify the applicable tests for all accessible surfaces.

Magnetic particle examination shall be conducted on all accessible surfaces of
ferromagnetic castings except machined gasket surfaces. Liquid penetrant
examination shall be conducted on all machined gasket surfaces of all materials and
on all accessible surfaces of non-ferromagnetic castings.
15- Include the following testing requirements for welds.
Radiographic examination shall be conducted after major welds for pressure
containing part. All weld repairs and post weld heat treatment shall conform to the
original material specification of the casting. All welding procedure specifications,
performance qualification records, and weld map documents must be available for
the purchaser inspector review upon his request.
Weld repairs of pressure containing castings shall be considered major if any of the
following conditions apply:
a) Castings leak during hydrostatic testing.
b) The depth of the repair cavity prepared for welding exceeds 20% of the wall
thickness or 25 mm (1 in), whichever is smaller.
c) The surface area of the repair cavity exceeds 65 cm² (10 in²).
All major weld repair procedures, including the welding procedure specifications (WPS),
with supporting documentation shall be prepared and submitted to the Buyer
Representative for review and approval by the SCC prior to any repairs being conducted.
All major repairs shall be documented. The documentation shall include the extent
of the repair, location, size, welding procedure specification, and detailed
photographs of the defect prior to any preparatory work and after preparation but
prior to the actual repair.
If the location of the defect cannot be clearly defined by photographic means, the
location shall be indicated on a sketch or drawing of the affected component.
or other standard method to meet the visual requirements of MSS-SP-55. Mould-
parting fins and remains of gates and risers shall be chipped, filed or ground flush.
17- The use of chaplets in pressure castings shall be held to a minimum. The chaplets
shall be clean and corrosion-free (plating is permitted), and of a composition
compatible with the casting.
Page 27 of 32
III- Technical Specification Sample for Wear Ring (Machined Part)

1- Specify the required wear ring material
Wear ring material shall be 316 SS with Stellite-6 weld overlay on the outside diameter.
2- Specify the total quantity

Quantity: 4
3- Use the pump datasheet to specify the pump parameters according to 8.7
Pump Parameter
v- Maximum allowable working pressure = 550 psig.
Note: Since none of SAEP-365 paragraph 8.7 limits are exceeded, contacting CSD to
specify additional testing is not required.
4- Include the dimensions and tolerances

Dimensions and tolerances shall be as per the below drawing.
Page 28 of 32
5- Indicate the pumps service.

Service: Sweet Crude Oil. This is not a sour application (no H 2S).
and testing requirements specified in this technical specification and Inspection
Requirement Form 175-791100.
Note: Since none of SAEP-365 paragraph 8.7 limits are exceeded, no addition testing
other than Inspection Requirement Form 175-791100 is required.
7- State that all subcontracted work, such as balancing, heat treatment and hard coating,
shall be done at an approved Saudi Aramco facility (contact MSSD/CR&OU for the
approved list). All applicable NDTs shall be done per ASME BPVC, Section V.
Machining of parts shall be done at a Saudi Aramco approved facility under 9COM #
6000011675. The spare part manufacturer shall refer to Saudi Aramco MSSD for list
of approved facilities.
Page 29 of 32
IV- Technical Specification Sample for Vertical Pump Suction Bell (Non-
Pressure Retaining Part)
Original casing material: NI-resist cast iron ASTM A436 Type 2.
New casing material: Same material.
2- Specify the required quantity

Quantity: 1
3- Use the pump datasheet to specify the pump parameters in paragraph 8.7.
Pump Parameter
i- Pump speed = 1800 rpm

Note: Since none of SAEP-365 paragraph 8.7 limits are exceeded, contacting CSD to
specify additional testing is not required.
4- Specify the casing weight

Approximate part weight = 20 Lbs.
5- Indicate the pump service

Service: Waste water (no H2S)
meet ISO 15156. Since this is not a sour application (no H2S), hardness test is not
required.
6- 3D measurement is not required.

tolerances. Special focus shall be given to inlet vane thickness and outside wall
thickness, and overall part shape:
I. Vane angels shall be 90 ± 2 degree.
II. Unless otherwise agreed with purchaser, the tolerances for the general casting
wall thickness shall be +3/-1 mm.
Page 30 of 32
III. The general tolerances for general machined surfaces shall not be more than
0.05 mm (0.002 inch) and the tolerances for general machined length shall be
± 1.0 mm. Critical clearance and interference fits, shall be as indicated in
below drawing.
IV. Ensure that all radial machined surfaces are concentric.
V. Critical clearance and interference fits as shown in the below drawing shall be:
A = 10 in + 0.00x/-0.00y
B = 6 in + 0.00x/-0.00y
C = 3 in + 0.00x/-0.00y
A
C
and testing requirements applicable to a non-pressure retaining parts as specified in
this PO technical specification and Inspection Requirement Form 175-791200.
9- State that machining of parts shall be done at a Saudi Aramco approved facility
under 9COM # 6000011675. The spare part manufacturer shall refer to Saudi
Aramco MSSD for list of approved facilities if machining will not be done in-house.
10- Include the following testing requirements for welds.
If welding is done, all welding repairs and post weld heat treatment shall conform to
the original material inspection of the casting. All welding procedure specifications,
performance qualification records, and weld map documents must be available for
the purchaser inspector review upon his request.
Page 31 of 32
or other standard method to meet the visual requirements of MSS-SP-55.
Mould-parting fins and remains of gates and risers shall be chipped, filed or ground
flush.
12- Include pictures of the original part.
Page 32 of 32

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Engineering Procedure

SAEP-365 26 September 2016

Appendix A - Re-Engineering Facility

Previous Issue: 6 September 2011 Next Planned Update: 26 September 2019

©Saudi Aramco 2016. All rights reserved.

1.3 Additional requirements may be included in Scopes of Work, Drawings, or other

2 Conflicts and Deviations

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

Saudi Aramco Inspection Requirements

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

International Standards Organization

Manufacturers Standardization Society

4 Definitions and Acronyms

9COM: Commodity Number.

CR&OU: Contracted Repair & Operation Unit

Quality System: Organizational structure, procedures, processes and resources needed

Reverse Engineering: The process by which a mechanical component can be modeled

SAEP: Saudi Aramco Engineering Procedure

SCC: Standards Committee Chairman; Pumps, Seals and Mixers

5.3 It is the responsibility of ID&SSD to register new casting and fabrication

5.7 For pumps repaired by a non-Saudi Aramco repair facility, it is the

5.8 Non-destructive Testing Unit of the Operations Inspection Division shall be

6.1 Reverse engineering may only be considered when:

6.4 Approved spare parts manufacturers may be considered as an alternative

7 Applicable 9COM Listing

7.1 9COM number 6000012812: Re-Engineered Pump Components made by Casting.

7.2 9COM number 6000011675: Re-Engineered Pump Parts made by Machining or

8 Purchase Order Instructions and Specifications

As there are no specific standards addressing spare parts manufacturing, it is the

Impellers Pressure Retaining Casing Parts

When a 3D measurement is required, the manufacturer shall generate the 3D

8.4 Radiographic examination shall be conducted on cast impellers if the peripheral

Impellers shall be subjected to a fluorescent magnetic particle examination

Deviation from this requirement requires SCC approval.

Weld repairs of pressure containing castings, including impellers, shall be

All major weld repair procedures, including the welding procedure

If the location of the defect cannot be clearly defined by photographic means,

The Purchaser may require additional non-destructive examinations to verify the

8.9 Surfaces of castings shall be cleaned by sandblasting, shot blasting, chemical

8.10 Magnetic-particle or liquid-penetrant examination is required for auxiliary

8.11 For pressure retaining castings, magnetic particle examination shall be

8.12 For pressure retaining castings, radiographic examinations shall be performed

Radiographic examinations shall be performed on the pressure retaining castings

9 Manufacturing Facility Assessment Procedure

9.1 Facility Evaluation Phases

This section provides general guidelines to be considered by Saudi Aramco

9.1.1 Pre-Visit Phase

f) Obtain a copy of the ISO 9001 Certificate if the manufacturer is

i) Request a list of in-house and outsourced manufacturing activities

9.1.2 Facility Visit Phase

9.2 Quality Requirements and Evaluation

9.2.2 Qualification of none Saudi Aramco Non-Destructive Testing (NDT)

Upon completion of the plant assessment visit, a technical assessment report

Appendix A - Re-Engineering Facility Pre-Visit Survey Form

1.0 FACILITY INFORMATION

Company start up name & date:

3.0 PUMPS SPARE PARTS PRODUCT INFORMATION (Tick one Box)

3.3 Type of re-engineering measurement tools and methods. Manual Automated

3.4 What is your production limitation?

3.8 List all used casting methods:

5.0 PROCESS (Tick Box if applicable)