Engineering Standard

SAES-L-050 29 December, 1999

Construction Requirements
For Metallic Plant Piping
Piping Standards Committee Members
Chu, K.S., Chairman
Al-Sabti, R.A.
Al-Sannaa, M.A.
Al-Sharif, T.M.
Finman, L.S.
Hayden, D.M.
Kim, S.U.
Moore, E.M.
Mullen, M.A.
Poe, D.C.
Youngblood, A.D.

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................ 2
2 Conflicts And Deviations............................... 2
3 References.................................................... 2
4 Identification Of Materials............................. 3
5 Storage......................................................... 3
6 Handling........................................................ 3
7 Pipe Fit-Up And Tolerances.......................... 4
8 Fabrication.................................................... 5
9 Cleaning........................................................ 5
10 Buried Installation......................................... 7
11 Pressure Testing........................................... 8

Appendix A ,- Flanged Joints Assembly

Procedure...................................................... 9

Previous Issue: 1 December, 1996 Next Planned Update: 1 December, 2002

Revised paragraphs are indicated in the right margin Page 1 of 15
Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

1 Scope

This standard supplements ASME B31.3 code and defines additional requirements
governing the fabrication and installation of metallic plant piping as well as piping
assemblies such as jumpovers for cross-country pipelines.

2 Conflicts And Deviations

2.1 Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Materials System Specifications (SAMSSs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.

3 References

The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Requirement
SAEP-1024 Chemical Cleaning of New Boilers

Saudi Aramco Engineering Procedure Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-H-200 Storage, Handling and Installation of Externally
Coated Pipe
SAES-G-116 Cleanliness Standard for Lube/Seal Oil Fluid
Power Systems
SAES-L-003 Design Stress Criteria for Pressure Piping
SAES-L-009 Metallic Flanges, Gaskets and Bolts

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

SAES-L-010 Limitations on Piping Joints

SAES-L-011 Flexibility, Support and Anchoring of Piping
SAES-L-012 Design of Piping Systems Inside Plant Areas
SAES-L-051 Construction Requirements for Cross-Country
Pipelines
SAES-L-056 Pressure Testing of Plant Piping and Pipelines
SAES-W-011 Welding Requirements for On-Plot Piping
SAES-X-600 Cathodic Protection of Plant Facilities

Saudi Aramco Materials System Specifications

01-SAMSS-010 Fabricated Carbon Steel Piping
01-SAMSS-017 Auxiliary Piping for Mechanical Equipment

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME B31.3 Process Piping

4 Identification Of Materials

All pipe and fittings shall have the material specification and grade stamped, stenciled,
or otherwise marked.

5 Storage

5.1 Pipe shall not be stored directly on the ground. Pipe shall be placed on mounds
or sleepers.

5.2 Stacking shall be made in a manner to avoid damage to pipes or coatings. Refer
to SAES-H-200.

5.3 Fittings and valves shall be stored in shipping crates or on racks.

5.4 End protectors on flanges, weld bevels, threads, and socket ends shall be firmly
attached.

6 Handling

6.1 All material shall be handled with care during fabrication and installation to
prevent damage.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

6.2 Lined and coated pipes and fittings shall be lifted with wide fabric or rubber-
covered slings and padding shall be used to prevent damage to lining or coating
in accordance with SAES-H-200.

7 Pipe Fit-Up And Tolerances

7.1 The tolerance for axial dimensions, face-to-face, center-to-face and location of
attachments shall be ± 3 mm maximum.

7.2 Flattening of bends, measured as the difference between the largest and the
smallest outside diameter at any cross section, shall not exceed 5% of the
nominal diameter of the pipe. Flattening of bends at weld ends shall not exceed
3% of the nominal pipe diameter.

7.3 Lateral transition of branches and connections from the centerline of the run
shall not exceed ± 1.5 mm.

7.4 Flange bolt holes shall straddle the established centerlines. Rotation of flanges,
measured as the offset between elevation of bolt holes on opposite sides of a
flange centerline, shall not exceed ± 2.4 mm.

7.5 The tilt of a flange measured at the periphery across any diameter shall not
exceed 1.6 mm from the square position.

7.6 For piping over 3-inch NPS connected to machinery/equipment, flange

alignment shall be within the following limits unless piping analysis per SAES-
L-011 shows that loads and moments are within the manufacturer's limits for the
machinery/equipment nozzle:

a) Vertical bolt hole offset: ± 2.4 mm

b) Horizontal bolt hole offset: ± 2.4 mm

c) Rotational offset: ± 2.4 mm

d) Flange face tilt across diameter: 0.001 inch per inch of flange outside
diameter up to a maximum of 0.030 inch, and 0.010 inch for all flanges
with an outside diameter less than 10 inches.

e) Flange face separation, gasket thickness: ± 1.6 mm

f) Combination of vertical, horizontal and rotational offset: ± 3.2 mm

If a spectacle plate is installed between two flanges, these tolerances can be

increased by 30% except for tolerances for flange face tilt across diameter and
flange face separation.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

If these tolerances can not be met when connecting the existing piping to new
equipment, the actual misalignment and piping layout shall be reviewed and
approved by the Chairman of Piping Standards Committee in CSD.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Commentary Note:

When a piping flange is aligned to a machinery flange, the machinery alignment

should be within the equipment vendor specified tolerances, after the stud bolts
of the connecting flanges are removed following the completion of piping
assembly.

8 Fabrication

8.1 Shop fabrication of piping shall be in accordance with 01-SAMSS-010. All

welding and weld inspection of piping shall be in accordance with SAES-W-
011.

8.2 Refer to SAES-L-010 for piping joints and limitations.

8.3 Flanged Joints

8.3.1 Refer to SAES-L-009 for flanged joints.

8.3.2 The flange joints should be assembled and bolts tightened in accordance
with Appendix A of this standard.

8.3.3 Deviation from Appendix A for less critical services shall be resolved by
mutual agreement among proponent representative, SAPMT, Inspection
and the Piping Committee Chairman or his representative.

8.4 If post-weld heat treatment (PWHT) of pipe spools is required (refer to SAES-
W-011), non-pressure containing welded attachments such as shoe support for
insulated lines, dummy extensions and legs, and wear pads shall be welded to
the pipe spools before stress relieving. PWHT of piping spools with flanged
joints shall be done before flange assembly.

8.5 The inside surface of welded joints at orifice flanges shall be ground or
machined smooth.

9 Cleaning

9.1 Prefabricated pipe spools shall be visually inspected for cleanliness, and shall
have foreign material removed from the inside, and shall have end protectors
installed.

9.2 After assembly and installation, the piping shall be cleaned inside to remove all
loose material. The cleanliness shall be verified visually and/or by video
inspection techniques. Use any combination of the following techniques to
effect cleaning.

9.2.1 Water flushing

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

9.2.1.1 Equipment which is sensitive to damage during water flushing

shall be removed, blocked off or isolated. A list shall be
prepared and be part of the flushing procedure. Ball valves
shall be flushed in fully open position.

9.2.1.2 All piping systems shall be flushed using high pressure (60.8
mPa (8.8 ksi) minimum) jet such as rotating hose or rotating
nozzle.

9.2.1.3 Below 4", use High Velocity Water Flushing (HVWF). On

systems where high pressure jet flushing cannot be used due to
complicated shapes and/or long runs use HVWF or slug
flushing. Water velocity shall be a minimum of 3 m/s.

9.2.1.4 The flushing medium shall be in general fire water. When

flushing stainless steel lines, the chloride ion content shall be
less than 50 mg/L. After flushing, the piping systems shall be
completely drained, dried to a dew point below –1 °C and
protected against corrosion.

9.2.2 Pneumatic flushing with dry air (dew point –1 °C or less) or steam with a
minimum exit velocity of 15 m/s. Repeat flushing until cleanliness is
verified by observing the absence of any solids impact on a polished
metal target at the exit.

9.2.3 Pressurized Air Shock Blowing (PASB)

9.2.3.1 Use PASB for initial cleaning for instrument air, plant air and
as an alternative method for initial cleaning of small bore pipe
(less than 2 inch). Use PASB if there are problems removing
trapped liquid in the piping, or to verify cleanliness of small
bore pipe where video inspection is impossible or inadequate
due to pipe dimension or configuration.

9.2.3.2 The air shocking pressure shall never exceed the working
pressure of the system and shall never be more than 810 kPa
(117 psi). Safety precaution shall be taken when this method is
used.

9.2.3.3 Repeat PASB until cleanliness is verified by observing the

absence of any solids impact on a polished metal target at the
exit.

9.2.4 Mechanical scrapers

9.3 Chemical or Vapor Phase or Foam cleaning

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

9.3.1 The interior of carbon steel piping for the following specific services
shall be cleaned after hydrostatic pressure testing to remove oil, grease,
preservatives, rust and mill scale per approved procedures. (refer also to
01-SAMSS-017, SAES-G-116, SAEP-1024).

9.3.1.1 Boiler feed water and steam condensate

9.3.1.2 Lube oil and seal oil

9.3.1.3 Seal gas supply piping

9.3.1.4 Steam supply line to turbines

9.3.1.5 DGA, TEG, and Refrigerant systems

9.3.1.6 If necessary to meet service fluid quality

9.3.2 Chemical or Vapor Phase or Foam cleaning shall be done by qualified

chemical cleaning contractors. Contractors shall submit for CSD
approval written cleaning procedures describing in detail the steps for
degreasing, descaling, neutralization, and passivation.

9.3.3 Lines to be chemical cleaned shall be identified on the P&ID's and Line
Index. The systems to be cleaned shall have high and low point vents
and drains installed.

10 Buried Installation

10.1 Buried metallic plant piping (if permitted by SAES-L-003) shall have corrosion
protection in accordance with the applicable Saudi Aramco Coating Standards
and SAES-X-600. Buried installations shall comply with requirements in
SAES-L-051.

10.2 The minimum cover in paved or stabilized areas shall be in accordance with
SAES-L-012.

11 Pressure Testing

Hydrostatic testing of internal pressure piping shall be in accordance with SAES-A-004

and SAES-L-056.

Revision Summary
29 December, 1999 Major revision.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Appendix A - Flanged Joints Assembly Procedure

A-1 Scope

A-2 This procedure defines minimum requirements for flanged joints assembly
including bolts tightening. Contractor shall be responsible to assure that proper
leak proof joints are achieved.

A-3 Pre-assembly Inspection

A-3.1 Bolts shall be visually checked for proper size, dimension and for any
physical damage to shanks or threads which would interfere with bolt
assembly or performance. Also, check the material and suitability of
the stud bolts for service temperature.

A-3.2 The flange facing, particularly the seating area, shall be visually
examined for cleanliness and insure that no damage, such as scratches
exist.

A-3.3 The gasket shall be verified for correct type, rating, and dimension.
Also, it shall be free from any damage particularly in the seating
element. Insure that spiral wound gaskets are stored flat specially for
large sizes, 24 inch and larger.

A-3.4 Verify that proper lubricant is used. Lubricant for bolts and nuts shall
be Jet-Lube SS-30 or other acceptable lubricants listed in Table A.1.

A-3.5 Tightening tools shall be checked for adequacy, performance and

calibration, if required.

A-4 Torque values vary according to flange rating, bolt size, type of gasket, and
friction factor of the lubricant.

The torque values are specified in Tables A-2 and A-3.

Table A-2 applies to all gasket listed in SAES-L-009, except for isolating
gaskets, based on a friction factor of 0.10, using graphite and oil.

Table A-3 applies to isolating gaskets (e.g. Pikotek), based on a friction factor of
0.125.

Table A-4 are torque values for various flange ratings, bolt sizes and friction
factors.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

A-5 Torquing Tools:

A-5.1 There are various types of tools available to achieve the proper torque
value. Selection of the proper tool depends on the stud bolt size,
physical location of the flanged joint, and criticality of the flange.
Identifying the proper tools shall be resolved between Contractor,
SAPMT, Proponent and Inspection prior to commencing the erection
of the piping.

A-5.2 The manufacturer's instructions shall be followed for the operation,

limitation and maintenance of all torque wrenches used to perform
flange bolts tightening.

A-5.3 Torque wrench calibration shall be performed in accordance with

manufacturer's recommendations, or as required by the inspector after
consultation with Piping Specialist in Consulting Services Department.

A-6 Stud Bolt Tightening Procedure

Step 1: Align flanges and gasket. Clamp securely in place.

Step 2: Apply lubricant to stud threads over length and nut engagement and to
face of nut which contacts flange. Insure that the nuts run freely down
the thread of the studs.

Step 3: Install all studs and nuts hand tight, insure that studs pass freely
through the flange holes. Position the nut on one end of the stud such
that only the crown of the stud projects beyond the face of the nut. The
excess stud length should project beyond the nut on the other side.
Commentary Note:

By doing this, the nut that is installed nearly flush with the end of the stud can
be easily removed since the threads are not coated, and normally have not
been subjected to corrosion. The side of the stud with the flush nut should be
chosen by taking into consideration factors such as whether one side has better
access for maintenance personnel and/or tightening tools, e. g., torque wrench
or impact wrench, etc.

Step 4: Number each stud according to its position in the flange as shown on
Figure A.1. Stud Bolt Tightening Sequence.

Step 5: Tighten studs per Stud Bolt Tightening Sequence with an appropriate
tool such as air impact wrench or equal.

Step 6: For joints containing RTJ or Spiral Wound Gaskets, repeat step 5.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Step 7: Tighten the stud bolts in stages to obtain the final required torque from
the appropriate torque table. The first stage should not be more than
30% of the final torque. Apply the torque evenly to each stud
following the stud bolt tightening sequence. The final torque must be
within ± 5 percent of the required values per paragraph A-4.

A.7 Stud Bolt Additional Tightening Procedure Where Leaks Occur During Pressure
Testing.

Step 1: Depressurize the piping system and retorque stud bolts to maximum
torque value shown on table.

Step 2: If leak does not stop after retorquing has been performed, disassemble
the flange joint and inspect as follows:

a. Inspect stud bolts and nuts for defects or damage to threads or

improper cleaning of threads.
Commentary Note:

Do not use wire brushes to clean threads.

b. Inspect flange faces for damage, misalignment.

c. Inspect gasket for damage or defects.

Step 3: After all defective and damaged items have been repaired or replaced,
reassemble the flange joint using a new gasket and tighten the bolts
using the maximum torque values.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Table A-1 Friction Factors for Different Lubricants

Lubricants Friction Factors Torque Correction

Factor
Moly Graphite .06 0.67
Tool Joint Compound .08 0.8
Graphite and Oil .10 1.0
(used as the base line for torque values
in Table A-2)
Aerocote #4 .11 1.1
KOPR-KOTE .11 1.1
EL-PRO C5A .11 1.1
FEL-PRO C100 .11 1.1
FEL-PRO C102 .11 1.1
(commonly called Anti-Seize)
Jet Lube SS-30 .12 1.2
API Bul. 5A2 .13 1.3
Thread Compound
Light Machine Oil as shipped .15 1.5
Dry Bolts .2 2

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Table A-2 Torque Value For A193 B7 And B7M

Stud Bolts With A194 2H And 2HM Nuts

Stud Bolt Torque Torque

Size Minimum Maximum
inch Ft-Lb Ft-Lb
1/2 30 34
9/16 43 49
5/8 60 68
3/4 107 120
7/8 170 190
1 256 287
1-1/8 374 420
1-1/4 524 590
1-3/8 709 798
1-1/2 934 1051
1-5/8 1201 1351
1-3/4 1515 1704
1-7/8 1879 2113
2 2296 2583
2-1/4 3311 3724
2-1/2 4151 5155
2-3/4 6150 6918
3 8033 9037
3-1/4 10,253 11,545
3-1/2 12,872 14,481
3-3/4 15,901 17,888
4 19,356 21,775

Note (1): Torque values based on 0.12 Average Friction Factor and 30,000 psi
prestress on stud bolts. A combination of various elements such as the
conditions of the threads, the condition of the flange to the nut bearing
surface and the type of lubricant used, makes up the friction factor which
can vary from .04 to .20 or as much as 500%.

Note (2): Torque values for stainless steel or other alloy stud bolts can be obtained by
multiplying the ratio of the specified minimum yield strength (SMYS) of
stainless steel stud bolts to A193 B7 stud bolts, to the torque values in the
table. The SMYS values for all bolting materials are listed in Table A-2 of
ASME B31.3 code (Note: SMYS depends on grade, class and size).

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Table A-3 Torque Values For Isolating Gaskets (Pikotek) On ASME B16.5
And ASME B16.47 Series A & B, Class 150 Through Class 2500 Flanges

Stud Bolt Size Torque Minimum

inch Ft-Lb
1/2 30
5/8 60
3/4 100
7/8 160
1 245
1-1/8 355
1-1/4 500
1-3/8 680
1-1/2 800
1-5/8 1100
1-3/4 1500
1-7/8 2000
2 2200
2-1/4 3180
2-1/2 4400

Note (1) Torque values based on 30,000 psi tension load and 0.125
Friction Factor from API-5A2 thread compound. See Table
A-2 Note (1) for other factors.

Commentary Notes:

(a) For ASME Class 900 through Class 2500, API-6B and API-6BX
Class 2000 through Class 15000, and RTJ Flanges, the maximum
compressive stresses induced during installation should not exceed
25,000 psi. Design to 12,500 psi when possible.

(b) Calculations for compressive stresses applied during torque-up

procedures must account for ring joint grooves, gasket seal grooves,
raised face diameters, and gasket inside diameter. (See PIKOTEK
Gasket User's manual)

(c) Bolt tensioning equipment such as HYDRATIGHT may be used for

class 900 and above resulting in a minimum residual bolt stress of
30000 psi and a maximum of 50000 psi. Refer to PIKOTEK Gasket
User's manual for specific bolting instructions.

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Document Responsibility: Piping SAES-L-050
Issue Date: 29 December, 1999 Construction Requirements
Next Planned Update: 1 December, 2002 For Metallic Plant Piping

Figure A-1 - Stud Bolt Tightening Sequence

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