Shop and Field Fabrication - PR - 0XX

DOCUMENT TITLE:
SHOP AND FIELD FABRICATION PROCEDURE
Document No: Revision

No: 00
PREPARED CONTROLLED APPROVED

REV DATE ISSUED FOR
BY BY BY
REVIEW AND
00
APPROVAL
LUKKA RK HAIDER
SA - PID
QA QC
Document No:
Document Issue Purpose
: For Approval : For Review□: For Information □: For Construction □: As Built
.
DOCUMENT TITLE:
Document No: Revision No:

BQ-ZUL-CON-QAC-PR-0XX 00
CONTENTS
1. PURPOSE .................................................................................................................................. 3
2. SCOPE ...................................................................................................................................... 3
3. DEFINITION ............................................................................................................................. 3
4. REFERENCES ........................................................................................................................... 3
5. EQUIPMENT, PERSONNEL & SHOP AREA............................................................................... 4
5.1 EQUIPMENT & TOOLS ............................................................................................................. 4
5.2 STAFF.................................................................................................................................... 4
5.3 WORKERS .............................................................................................................................. 4
5.4 SHOP AREA ........................................................................................................................... 4
5.5 RESPONSIBILITY:.................................................................................................................... 5
6. PROCEDURE: ........................................................................................................................... 5
6.1 STORAGE AND HANDLING ....................................................................................................... 5
6.2 CUTTING AND BEVELING: ........................................................................................................ 6
6.3 JOINT ALIGNMENT: ................................................................................................................. 7
6.4 CLEANING:............................................................................................................................. 8
6.5 TACK WELDS: ........................................................................................................................ 8
6.6 PRE HEATING:........................................................................................................................ 8
6.7 WELDING: .............................................................................................................................. 9
6.8 FLUX AND SLAG REMOVAL: .................................................................................................. 10
6.9 CONSUMABLE ITEM .............................................................................................................. 10
6.10 WEATHER CONDITION .......................................................................................................... 10
6.11 Weld Identification………………………………………………………………………………...11
6.12 Pipe Fit-Up and Tolerances………………………………………………………………………11
6.13 Pipe Spools Cleaning/Flushing……………………………………………….........................12
6.14 Pipe Hangers and Supports……………………………………………………………………..13
7. PROCEDURE: ......................................................................................................................... 14
7.1 WELD REINFORCEMENT ........................................................................................................ 14
7.2 INSPECTION: ........................................................................................................................ 15
7.3 REPAIRS: ............................................................................................................................. 16
7.4 PAINTING ............................................................................................................................. 16
7.5 FIELD FABRICATION AND INSTALLATION ................................................................................ 17
8. ATTACHMENTS ..................................................................................................................... 18
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1. PURPOSE
The purpose of this procedure is to describe the system and Constructability of the Shop / field
fabrication for carbon steel Pipe.
2. SCOPE
This procedure covers the requirements for the system and constructability of the Fabrication shop
for carbon steel Pipe which will include the following.
❖ Storage and Handling

❖ Fabrication
❖ Welding
❖ Inspection
3. DEFINITION
❖ IFC Issued for Construction
❖ ANSI American National Standards Institute
❖ AISC American Institute of Steel Construction
❖ AWS American Welding Society
❖ ASTM American Society For Testing And Materials
❖ NMR Non Material Requirement
❖ PPE Personnel Protective Equipment
❖ RFI Request For Inspection
❖ NCR Non Conformance Report
4. REFERENCES
❖ SAES-L-350 Construction of Plant Piping
❖ SAES-L-105 Piping Material Specification
❖ SAES-L-460 Pipeline Crossing under Roads and Rail roads.
❖ SAES-L-450 Construction of On-Land and Near-Shore Pipelines
❖ SAES-H-200 Storage, Handling and Installation of Externally Coated pipe.
❖ SAES-L-110 limitation on Piping Joints and Components.
❖ SAES-W-011 Welding Requirement for On-Plot Piping.
❖ SAES- W 012 Welding Requirements for Pipelines
❖ ASME-B31.3 Process Piping
❖ ASME- 16.5 Pipe Flanges and Flanged Fittings
❖ ASME-16.25 Butt welding End
❖ 01-SAMSS-010 Fabricated Carbon Steel Piping.
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5. EQUIPMENT, PERSONNEL & SHOP AREA

5.1 Equipment & Tools
❖ Calibrated Welding Machines
❖ Calibrated Welding Quivers
❖ Calibrated Welding Ovens
❖ GTAW & SMAW Welding Consumables
❖ Crane
❖ Fork Lift
❖ Boom Truck
❖ Grinders 4.5” and 7.5”
❖ Gas Cutting Set
❖ Spirit Levels
❖ Tri Square Sets
❖ Meter Tapes
❖ Steel Stands for piping spools
❖ Hydraulic Jacks (Capacity 2 Tons)
5.2 Staff
❖ Project Manager
❖ Construction Manager
❖ QA/QC Manager
❖ Piping Engineer
❖ QA/QC Inspector
❖ HSE Officer
5.3 Workers
❖ Foreman
❖ Fitter
❖ Welder
❖ Crane Operator
❖ Helper
5.4 Shop Area

❖ Covered Area of 15m X 8m having height of 5m will be made as fabrication shop.
❖ The covered area will be concreted.
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❖ One table (1.2m X 2.4m) having the CS sheet as its top will be provided.
❖ One vice will also be provided having capacity to hold Ø8” pipe.
❖ Power supply will be given to the fabrication shop.
❖ There will be halogen lights for the night time working.
5.5 Responsibility:
5.5.1 The Project Manager is the overall responsibility of the project activities process or
execution.
5.5.2 The Safety Officer is responsible for the development, implementation and
maintenance of safety policy. He shall co-ordinate with the project engineer, supervisor,
foremen and multicast care deployed under the project for its successful
implementation.
5.5.3 The QC Supervisor/ QC Engineer shall report to the QC Manager for all quality
implementation supports.
5.5.4 The QC Engineer and QC inspector shall review all quality related documents, material
certificates and non-conformance prior to taking any action.
5.5.5 The fabrication shop foreman and safety officer are jointly and severely responsible
for all the observances of all safety precaution required by BQ Safety Plan and
applicable to the manufacturer safety plan and applicable to the manufacturer safety
recommendation.
5.5.6 The QC Inspector shall be responsible for the preparation of necessary documents for
inspection.
5.5.7 The QC Supervisor shall review all request for inspection (RFI) forms initiated by QC
inspector and to mark as summary reports on daily basis.
6. PROCEDURE:
6.1 Storage and Handling
6.1.1 Pipe shall not be stored directly on the ground. Pipe shall be placed on mounds or
sleepers.
6.1.2 Stacking of pipes shall be made in manner to avoid damage to pipes or coatings (SAES-
H-200)
6.1.3 Fittings and valves shall be stored in shipping crates or on racks.
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6.1.4 End Protectors on Pipes, flanges, weld bevels, thread, and socket ends shall be firmly
attached.
6.1.5 CS and galvanized pipes shall be stored separately.
6.1.6 During off loading, pipes shall not be dropped on the transport, a crane and suitable
certified slings shall be used. Nylon slings will be used to handle coated piping and
fittings.
6.1.7 The assembly of bolted flanges joints shall be in accordance with SAEP-351
6.1.8 Pipe shall not be rolled or dropped off trucks
6.1.9 Internally coated pipe shall be handled from the outside Diameter only.
6.1.10 Slings for lifting pipe shall be nylon similar material to prevent damage to the pipe
surface. Wire rope slings are not to be used.
6.2 Cutting and Beveling:

6.2.1 The Pipes shall be cut as per dimensions mentioned in the isometric.
6.2.2 All pressure –containing welds, except for socket welds, shall be made with full penetration
groove weld only.
6.2.3 All pressure containing weld, including socket weld, shall be made with multiple passes.
6.2.4 Full penetration groove joints with included angles less than 30 degree (except for portions
of compound bevels) shall not be used without approval.
6.2.5 For branches with reinforcing pads, the branch attachment weld shall be completed and
inspected prior to installing the reinforcing pad.
6.2.6 Consumable inserts may be used for all application providing the composition matches the
weld metal composition.
6.2.7 The joint should be free of grease, oil, scales, rust or other foreign material.
6.2.8 The primer paint coat on pipe and fitting ends shall be removed prior to bevel end
preparation.
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6.2.9 Permanent backing rings or strips shall not be used except for the backing strips on sleeve
longitudinal welds. Vents and drains in accordance with SAES-L-110 shall not be installed
unless included in the approved design drawings.
6.2.10 Drains shall not be installed at the bottom of the pipe for buried pipelines.
6.2.11 When a length of pipe is cut from a longer joint of pipe, all vendor markings and other
identifying information shall be transferred to each length of pipe.
6.2.12 A 6mm weep hole shall be drilled for all dummy supports. The weep shall be located near
the base plate for all vertical dummy supports, and near the run pipe at 6 O’clock position
for all horizontal dummy supports.
6.2.13 Each spool shall be marked with a unique number.
6.2.14 The details of piping isometric breakdown into spools and joints will be recorded for
references.
6.3 Joint Alignment:

6.3.1 The fit up of pipe ends, fittings and weld neck flanges shall be done to obtain uniform root
opening, the criterion given in related WPS shall be followed.
6.3.2 Piping components shall be adequately supported and aligned by means of jigs, clamps
or their suitable devices during tacking.
6.3.3 Cold pulling shall not be allowed to alignment.
6.3.4 For pipe ends of the same nominal wall thickness, the offset shall not exceed 1.5mm.
6.3.5 If the large offset is caused by dimensional variations, it shall be equally distributed around
the circumference of the pipe.
6.4 Cleaning:
6.4.1 Surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides and other
materials detrimental to welding.
6.4.2 Cleaning shall be done in a manner that will not lead to any contamination of the weld or
base metal.
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6.4.3 All pipes to be internally cleaned of any foreign material before welding.
6.4.4 Upon completion of each welding pass, the weld shall be cleaned of spatter, slag and flux
deposits.
6.5 Tack Welds:

6.5.1 All tack welds shall be made in accordance with approved welding procedure and shall be
performed by qualified welders.
6.5.2 Tack welds shall be of sufficient cross section and length in order to avoid cracks.. The
recommended tack size is 3.2-4.8 mm and length is 12.5-25.4.
6.5.3 Tack welds incorporated into the final weld shall be ground to a feather at each end to
ensure adequate fusion on the root pass.
6.5.4 If any crack is found in the tack weld, it should be grind to the base sound metal before
welding and MT / PT should be done to ensure no defect in the base metal before welding.
6.6 Pre Heating:

6.6.1 Preheating shall be in accordance with the qualified WPS.
6.6.2 Preheat should be applied uniformly around the circumferential weld using gas or electrical
means.
6.6.3 Pre heat shall be measured minimum 75 mm away from the bevel end.
6.6.4 If a weld joint is wet or has surface moisture or condensation, it shall be dried by heating
for a distance of 100 mm from the weld joint and shall be warm to the hand before welding.
6.6.5 Minimum 25 mm of the bevel end shall be cleaned thoroughly to near white metal.
6.6.6 Temperature shall be measured using contact thermometer or indicating crayons of the
melting type.
6.7 Welding:
6.7.1 Each joint will be welded by the qualified welder and the qualified welding procedure (WPS)
shall be used.
6.7.2 The GTAW process shall be used for all passes for butt weld and socket weld in piping
and nozzles less than 33.4 mm OD. This does not apply to Weldolet, Sockolet,
Threadolets, and welding bosses.
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6.7.3 The second or hot pass shall be added as soon as possible after the completion of the root
pass, but shall not exceed 5 minutes for vertical down welding with cellulosic electrodes or
15 minutes for vertical up welding.
6.7.4 The pipe shall not be lifted or moved during welding.
6.7.5 Welds shall be made in sequences such that portions of welds do not remain uncompleted
before welding subsequent joints.
6.7.6 If any grinding reduces the base metal to less than the design minimum, the ground area
shall be re welded and ground flush with the original base metal surface or the component
shall be replaced.
6.7.7 Coated and clad or overlaid surfaces shall be protected from the welding arc, associated
weld spatter, and damage from ground clamps or other associated equipment.
6.7.8 Temporary attachments, back-up strips, or supports welded to any component shall be
made with a compatible material. Under no circumstances shall rebar or galvanized steel
be used.
6.7.9 The GTAW process shall be used for the root pass of butt welds in piping and nozzles of
60.3 mm OD (2”NPS) or less, except for vent and drain piping open to the atmosphere or
for carbon steel in low pressure water services. This does not apply to weldolets, sockolets,
threadolets, and welding bosses.
6.7.10 Adjacent weld beads shall be staggered and not started from the same location.
6.7.11 Sealing compounds or tapes shall not be used on joints that are to be seal welded.
6.7.12 Seal welding of threaded connection shall cover all exposed threads and shall have a
smooth contour between welds.
6.7.13 The minimum distance between parallel butt weld shall be 20 mm or three times the wall
thickness of the wall thickness of the joint, whichever is greater.
6.8 Flux and Slag Removal:

6.8.1 Weld beads shall be contoured to permit complete fusion at the side of the bevel and to
minimize slag inclusions.
6.8.2 Flux, slag and weld spatters shall be completely removed from weld beads and adjoining
material.
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6.9 Consumable Item

6.9.1 Welding consumables shall be selected based on their mechanical properties,
compatibility with the materials to be joined, their suitability for the intended services, and
consideration of polarity position, and direction of welding.
6.9.2 Electrodes and filler wires shall be kept clean and dry, and properly stored according to
manufacturer recommendation.
6.9.3 No Electrodes or filler wires that are damaged, damp greasy or oxidized may be used.
6.9.4 Low Hydrogen electrodes shall be placed in a holding oven and held at a minimum 120°C
for at least 2 hours prior to use.
6.9.5 Welding electrodes shall be issued for production from holding ovens only and shall be
placed in heated quivers capable of maintaining minimum temperature of 65° C.
6.9.6 After 04 hours (or 08 hours when electrodes have been placed in heated quiver), the
electrodes must brought back to the holding oven at 120°C for 4 hours.
6.9.7 The root pass of single sided groove welds without backing in P. No. 1 carbon steels may
be made with an E XX10 electrode.
6.9.8 F- No. 1 &2 electrodes shall not be used on for pressure-retaining welds.
6.9.9 QA/QC Inspector shall monitor and assure the correct use of welding electrodes.
6.10 Weather Condition

6.10.1 Welding shall not be done when the quality of the weld would be impaired by the prevailing
weather conditions, including blowing sands or high winds.
6.10.2 Fire resistant windshields may be used when practical
6.10.3 If weather conditions become too severe, welding operations shall be stopped.
6.11 Weld Identification

6.11.1 All weld joints shall be marked for identification by a weld number and welder symbol.
These identifications shall be made with a suitable weather-proof marking material. The
markings shall be placed in a location such that they will be easily observed and remain
visible for a time suitable to the authorized Saudi Aramco inspector.
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6.11.2 The fabricator shall establish and submit for approval an identification system that shall
uniquely identify each member and weld joint. The identification system shall be used all
examinations, surveys, inspections, etc.
6.12 Pipe Fit-Up and Tolerances

6.12.1 The maximum tolerance for axial dimensions, face-to-face, center-to-face and location
of attachments shall be +/_ 3-mm.
6.12.2 Flattening of bends, measured as the difference of 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 and weld ends shall not exceed 3% of the nominal pipe
diameter.
6.12.3 Lateral transition of branches and connection from the center line of the run shall not
exceed +/_ 1.5mm.
6.12.4 Flange bolt holes shall be oriented as follows, unless otherwise indicated on the
construction drawings.
a) Flange face vertical –bolt holes to straddle vertical lines.

b) Flange face horizontal –bolt holes to straddle horizontal lines.
c) Rotation of flanges, measured as the offset between elevations of bolt holes on
opposite side of the flange centerline, shall not exceed +/_ 2.4mm.
d) The tilt of a flange measured at the periphery across any diameter shall not exceed
1.6mm from the square position.
6.12.5 For piping over 3-inch NPS and connected to machinery/equipment, flange alignment
shall be within the following limits unless piping analysis per SAES-L-120 shows that
loads and moments are within the manufacturer’s limits for the machinery/equipment
nozzle:
a) Vertical bolt hole offset :+/_ 2.4mm

b) Horizontal bolt hole offset :+/_ 2.4mm
c) Rotational offset :+/_ 2.4mm
d) Flange face tilt across diameter: 0.025mm per 25mm (0.001 inch per inch) of flange
outside diameter up to maximum 0.672mm (0.030 inch), and 0.254mm (0.010 inch)
for all flanges with an outside diameter less than 10 inches.
e) Flange face separation, gasket thickness :+/_ 1.6mm
f) Combination of vertical, horizontal and rotational offset :+/_ 3.2mm
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6.12.6 In the case where 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.
6.12.7 If the tolerances per paragraphs 9.1 through 9.5 cannot be achieved, the actual
misalignment and piping lay-out shall be reviewed and approved by the chairman of
Piping Standards Committee in CSD.
6.13 Pipe Spools Cleaning/Flushing

6.13.1 Detailed procedure for cleaning and flushing of the piping spools and systems shall be
established identifying acceptable methods that will be applicable for every individual
system category.
6.13.2 Prior to Installation

As a minimum and prior to installation and/or erection of pipe spools on the pipe
supports the following shall be conducted:
i. All pipes shall be internally cleaned by air blowing. In addition, for large diameter
pipes rag cleaning should be conducted if found practical.
ii. All prefabricated pipe spools shall be visually inspected for cleanliness, and have
foreign materials removed from the inside.
iii. The piping ends shall be covered after inspection and prevent unauthorized
removal of the end cover prior to making the joint to the succeeding section of the
piping.
iv. The method of covering the pipe ends shall be continuously observed until the
spools are connected to the succeeding section.
6.14 Pipe Hangers and Supports

6.14.1 Dummy Supports
i. Installing additional dummy leg supports other than those in the design drawings
shall not be installed without prior review and approval from the Chairman of Piping
Standard Committee or his representative.
ii. A 6-mm weep hole shall be drilled for all dummy supports. The weep hole shall be
located near the base plate for all vertical dummy supports, and near the run pipe
at 6 o’clock position for all horizontal dummy supports.
6.14.2 Low Friction Supports

If Teflon sheet or similar low friction materials are used to function as low friction
supports are to be installed, the following shall apply.
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i. Sliding surfaces shall be protected during all construction activities including

painting and sand blasting.
ii. Provision shall be made to allow angular adjustment of the bearing surfaces during
installation, so that even distribution of the load can be assured.
iii. Low friction supports shall be constructed such that sand or other debris cannot
accumulate on sliding surfaces (by making the top surface larger than the bottom
surface).
6.14.3 Spring Supports

i. The spring setting shall be verified that they matching the design requirements.
ii. The spring support shall be in full engagement with pipe.
iii. All springs shall be in compression, so that failure will not result in the complete
release of load.
iv. Spring shall be factory set to the calculated cold settings by means of travel stops.
Upper stops for load preset and lower stops for hydro-test shall be provided. These
stops shall be banded or locked in place so they easily be dislodged during erection
or hydro-test. The travel stops shall be painted red and shall have bright color tag
indicating “Remove-after-Hydro Test”.
v. Each spring hanger assembly must be capable of sustaining the load during hydro-
testing, which is equal to 2-times the operating load.
6.14.4 Hanger Rods

Generally rod hangers should be avoided as practical as possible. Even they were
specified on the design drawings, good workmanship and construction practices
should be exercised to replace them with rigid pipe supports
In case they are installed the following should apply:
i. Rod hangers shall not be used for lines 2” NPS and larger in liquid service or multi-
phase flow.
ii. All hangers shall be provided with means for vertical adjustment.
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iii. Suitable locking devices shall be used at all threaded connections of the hanger
assembly (double-nuts).
iv. Rod hangers shall be subjected to tensile loading only.
v. Practicality for replacing them with rigid pipe supports should be evaluated and
implemented during construction.
6.14.5 Support Spacing

Support spacing as detailed in the design drawings shall be followed. If for practicality
the spacing has to be altered, prior approval has to be granted and reviewed by the
Piping Standards Committee Chairman or his representative.
7. PROCEDURE:
i. The form for the WPSs and PQRs shall be as suggested in the respective code being used.
ii. Welding shall not commence until the welding procedure has been approved for application
by SA Inspector and returned to the fabricator.
iii. All WPSs, PQRs and Weld and line description Tables shall be available at the work site
for review at any time by the authorized SA Inspector.
7.1 Weld Reinforcement

7.1.1 Weld reinforcement shall be required by the table below.
Wall Thickness: T, mm (in) Height: h, mm (in)
T≤ 6 (1/4) h≤1.5 (1/16)

6<T≤ 13 (1/2)
h≤3 (1/8)
13<T≤ 25 (1) h≤4 (5/32)
T> 25 (1) h≤5 (3/16)
7.1.2 Arc strikes shall be avoided. Should this occur, however, the deposit shall be carefully
removed by mechanical means.
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7.1.3 All arc strikes shall be cleaned and inspected by PT or MT.
7.1.4 Weld surfaces shall be free of cracks, excessive porosity, slag inclusions and other defects
indicating poor workmanship.
7.2 Inspection:
7.2.1 Client representatives shall have free access to the work at all times.
7.2.2 Client representative shall have the right to inspect the fabrication at any state or stage
and to reject material or workmanship which does not conform to the specified
requirements.
7.2.3 The fabricator shall furnish, install, and maintain in a safe operating condition all necessary
shoring, scaffolding, ladders, walkways, and lighting for a safe and thorough inspection.
7.2.4 Visual Inspection shall be performed before, during and after welding and prior to any NDT.
7.2.5 All appropriate safety precautions shall be taken for each inspection method.
7.2.6 All NDT personnel shall be qualified in accordance with SAEP-1140 or SAEP-1142.
7.2.7 Inspection of all welds shall include a band of base metal at least 25.4 mm wide on each
side of the weld.
7.2.8 All weld preparation, fit-up and weld assemblies will be visually inspected in accordance
with approved ITP, whereas a separate procedure will be issued for welding consumable
control and general welding and its inspection.
7.2.9 Visual Inspection shall include:
• Joint Preparation & Cleanliness

• Fit-Up and internal alignment prior to welding
• Preheating
• Welding position and other parameters in the WPS
• Appearance of the finished weld
7.2.10 Non-Destructive examination for welded joints shall be in accordance with the NDT
Procedures.
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7.3 Repairs:
7.3.1 Welds may be repaired twice. If weld is still not acceptable after the second repair. Then
Client Inspection Representative has the sole authority for the decision to permit additional
repair attempts or to require that the entire weld be cut out.
7.3.2 Cracked welds (except for crater cracks) shall be cut –out unless a repair is approved by
the Client.
7.3.3 Repair welding shall be performed using a properly qualified and approved procedure.
7.3.4 All repaired welds shall, as a minimum, be inspected using the original testing method.
7.3.5 Any weld not meeting the acceptance criteria of the applicable code or standard shall be
cut or repaired.
7.4 Painting
7.4.1 All buried onshore pipes shall be externally coated.
7.4.2 The SAES-H-002 shall be used for below ground and SAES-H-001 shall be used for the
above ground.
7.4.3 Hand- applied tapes of all types shall not be used.
7.4.4 Bevel protectors, when used shall be firmly attached to pipe.
7.4.5 FBE coated pipes shall not be stacked directly against each other at any time during
storage or transportation.
7.4.6 Twelve meter joints of pipe shall have at least 3 full encirclement separation pads and
twenty four meter shall have at least 5 full encirclement separation pads.
7.4.7 The completed girth weld area on FBE coated pipes shall be externally coated in
accordance with SAES-H-201.
7.4.8 Damaged FBE coating shall be repaired as follows:
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• Areas smaller than 1450 mm use thermal melt sticks or an epoxy patching compound
approved by the Responsible Standardization Agency (RSA).
• Areas larger than 1450 mm and smaller than 0.2 m square use an epoxy patching
compound approved by the Responsible Standardization Agency (RSA).
• Areas larger than 0.2 mm square- use fast curing solvent free epoxy system only as
per APCS-113A.
• The repair coating shall overlap the adjacent sound coating by at least 10 mm to
maximum 20 mm.
7.5 Field Fabrication and Installation

7.5.1 Prior to Installation
As a minimum and prior to installation and/or erection of pipe spools on the pipe racks
and pipe supports the following shall be conducted:
7.5.1.1 All pipes shall be internally cleaned by air blowing. In addition, for large diameters pipes
rag cleaning should be conducted if found practical.
7.5.1.2 All prefabricated pipe spools shall be visually inspected for cleanliness, and shall have
foreign material removed from the inside.
7.5.1.3 The piping ends shall be covered after inspection to prevent unauthorized removal of
the end cover prior to making the joint to the succeeding section of piping.
7.5.1.4 The method of covering the pipe ends shall be part of the procedures.
7.5.2 During Assembly and Erection
7.5.2.1 During assembly and erection, the construction agency shall ensure that no foreign
materials (such as welding consumables, lumbers, gloves, etc.) are left inside the piping
system.
7.5.2.2 After assembly and installation, the piping shall be cleaned inside to remove all loose
material. The cleanliness shall be verified visually inspection techniques.
7.5.3 Buried Piping Installation
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7.5.3.1 Buried metallic plant piping (if permitted by SAES-L-310) shall have corrosion protection
in accordance with the applicable Saudi Aramco Coating Standards and SAES-X-600.
7.5.3.2 Buried installations shall comply with requirements in SAES-L-450 as applicable.
7.5.3.3 The minimum cover in paved or stabilized areas shall be in accordance with SAES-L-
460.
7.5.4 Transition Zones
7.5.4.1 The transition zones of the metallic piping from above ground to underground shall not
be encompassed by concrete or asphalt. A minimum of 1foot annuals of sweet sand
capped with aggregate shall surround the transition section.
7.5.4.2 At the transition point the external coating shall be extended from the below ground to
a minimum of 1 meter on the above ground section.
8. ATTACHMENTS
The following checklist, inspection forms and test records to document the compliance of the work
activities to the Project Quality Plan and other project requirements are to be filed and kept and to
be submitted to Saudi Aramco at the close of the project.
Quality Records to be used:
❖ Survey Report
❖ Field Fabrication Piping Checklist
❖ Shop Test Record (Radiography)
❖ Weld Radiographic Report
❖ Field Installation Checklist
All records of inspections and testing shall be safely kept and filed for Saudi Aramco’s review and
surveillance any time.
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Shop and Field Fabrication - PR - 0XX

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Shop and Field Fabrication - PR - 0XX

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DOCUMENT TITLE:

SHOP AND FIELD FABRICATION PROCEDURE

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SHOP AND FIELD FABRICATION PROCEDURE

PREPARED CONTROLLED APPROVED

Document Issue Purpose

: For Approval : For Review□: For Information □: For Construction □: As Built

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❖ Storage and Handling

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5. EQUIPMENT, PERSONNEL & SHOP AREA

5.4 Shop Area

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

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6.1.5 CS and galvanized pipes shall be stored separately.

6.1.8 Pipe shall not be rolled or dropped off trucks

6.2 Cutting and Beveling:

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6.2.13 Each spool shall be marked with a unique number.

6.3 Joint Alignment:

6.3.3 Cold pulling shall not be allowed to alignment.

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6.5 Tack Welds:

6.6 Pre Heating:

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6.7.4 The pipe shall not be lifted or moved during welding.

6.8 Flux and Slag Removal:

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6.9 Consumable Item

6.10 Weather Condition

6.10.2 Fire resistant windshields may be used when practical

6.11 Weld Identification

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6.12 Pipe Fit-Up and Tolerances

a) Flange face vertical –bolt holes to straddle vertical lines.

a) Vertical bolt hole offset :+/_ 2.4mm

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6.13 Pipe Spools Cleaning/Flushing

6.13.2 Prior to Installation

6.14 Pipe Hangers and Supports

6.14.2 Low Friction Supports

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i. Sliding surfaces shall be protected during all construction activities including

6.14.3 Spring Supports

ii. The spring support shall be in full engagement with pipe.

6.14.4 Hanger Rods

In case they are installed the following should apply:

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iv. Rod hangers shall be subjected to tensile loading only.

6.14.5 Support Spacing

7.1 Weld Reinforcement

Wall Thickness: T, mm (in) Height: h, mm (in)

T≤ 6 (1/4) h≤1.5 (1/16)

13<T≤ 25 (1) h≤4 (5/32)

T> 25 (1) h≤5 (3/16)

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7.1.3 All arc strikes shall be cleaned and inspected by PT or MT.

7.2.9 Visual Inspection shall include:

• Joint Preparation & Cleanliness

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7.4.3 Hand- applied tapes of all types shall not be used.