Material QC Engineer Questions | CBT

Aramco Preparation
This article is about Material QC Engineer Questions, who wants to prepare
material engineer interview at international company or Aramco based CBT
Test.

Quality Control Engineer General Responsibilities

1. Insuring quality control site surveillance.
2. Witness inspection and test in accordance with SATIP & SAIC.
3. Verifying the inspection reports and validating the results.
4. Shall continually inspect the work at site and all QA/QC documents shall be
managed by inspectorate and technical clerk assigned by the quality
department.
5. Monitor the timely production of the Inspection Certificate by construction
contractor or sub-contractor.
6. Ensure the proper disposition of the non-conformities with the assistance of
specialist as required.
Mechanical QC Engineer Responsibilities
1. Shall be Conduct an Inspection in accordance with International Code &
Standard.
2. Monitoring daily Piping activities.
3. Verify compliance according to project specification.
4. Preparing Quality Record.
5. Final acceptance documentation.
Material QC Engineer Questions | CBT Aramco
Preparation
Shall perform the receiving inspection according to SATIP & SAIC as follows:

1. Verifying that all required documents and records have been supplied by the
vendors.
2. Review Certified Material Test Report (CTMR) and other records received
from vendor.
 3. Perform visual check that the items have not been damaged during
transportation.
4. Verify that all items meet all requirement on material requisition.
5. Verify that the identification markings of the items are identical with CMTR
and other relevant document received from vendor.

UPON THE COMPLETION OF RECEIVING INSPECTION

Material Inspector shall prepare material receiving inspection report and shall
include the following:

6. Name of item received.

7. Serial ID Number.
8. Vendor Name.
9. Material Requisition Number.
10.Material Inspector Signature and Inspection Date.
AFTER COMPLETION OF RECEIVING INSPECTION
Material Inspector shall document the receiving inspection result on the
report and provide the copies to Material Control Supervisor and related
construction discipline department.

NON-CONFORMING ITEMS
Items found to be nonconforming at receiving inspection shall be clearly
identified and Controlled using Non Conformance Report (NCR) Procedure:
KGF-PM-6008-001, Segregate and place on the hold area and attached
“HOLD Tag”.

CAR – Corrective Action Request issued by the QA/QC manager to the

department responsible for nonconforming products.

MATERIAL RECEIVING
Before inspection takes place, construction department should submit
Request for Inspection (RFI) to the QA/QC department.

– RFI includes

o SAIC.
o Purchase Order.
o Delivery Note.
o Packing List.
o Certificate of Compliance.
o Equipment Test Report.
o Approved Data Sheet.
o Approved Drawings.
o Inspection Release Certificate.
o Inspection Disposition Reports.
– Verify and validate the above documents.
– Installation Manual.
– Perform the equipment, material pre-inspection.
– See to it that the materials and or equipment are free from defects or
damaged during transportation
– Material or Equipment shall be in accordance with company Material
Requisition, approved Standard and Specification.
– Fill in the necessary information on the checklist liked, name of the item
received, serial number, vendor name, material requisition, material inspector
signature, inspection date…
– Once the inspection was carried out all the pertaining documents should be
submitted to Saudi Aramco for signature and acceptance.

FINAL DISPOSITION REPORT includes the following:

– Narrative details of Quality activities performed during manufacturing and

fabrication of the equipment or material.
– Copies of Saudi Aramco approved waivers
– All SA-175 Contractor witness inspections.
– Copies of supplier Quality Records as specified in SA-175.
– Copies of all NCR’s with final dispositions and resolutions.
– Outstanding punch list items from pre-shipment inspections.
– Verify that all the requirements specified on the Saudi Aramco Inspection
Requirement Form 175-311500 have been met.

MATERIALS:
All pipe and fittings SHALL have the material specification and grade
stamped, stenciled, or otherwise clearly marked with permanent marking
method.
STORAGE:
The following requirements shall apply to storage areas relevant to the
particular project which includes, but no limit to, layout yards, receiving areas,
warehouse etc.

1. Pipe shall not be stored directly on the ground. Pipe shall be placed on
mounds or sleepers.
2. Stacking of pipe shall be made in a manner to avoid damage to pipes or
coating. Refer to SAES-H-200
3. Fittings and valves shall be stored in shipping crates or on racks.
4. End protector on pipes, flanges, weld bevels, threads, and socket ends
SHALL be firmly attached.

HANDLING:
1 Lined and coated pipes and fittings shall be lifted with wide fabric or rubber
covered slings and padding’s shall be used to prevent damage to lining or
coating in accordance with SAES-H-200.
 SAUDI ARAMCO, API, ASME AND
ASTM Standards for QC Engineers
This article is about SAUDI ARAMCO, API, ASME AND ASTM International
Standards and Codes for QC Engineers related to topic of Quality system
inspection for Petrochemical plants. This documents and notes can be useful
for who are attending CBT Aramco Test or other international test for QC
Inspector or Engineer.

SAUDI ARAMCO, API, ASME AND ASTM Standards for QC Engineers

SAUDI ARAMCO, API, ASME AND ASTM

Standards for QC Engineers
1. SCHEDULE “Q” Contractors Quality Requirements.
2. SAER 1972 Inspection Requirement (SA Material Inspection & Testing).
3. G.I 0002.102 General Instruction Pressure Testing Safety.
4. SAES-A-004 General Requirements for Pressure Testing.
5. SAES-A-005 Safety Instruction Sheet.
6. SAES-A-007 Hydrostatic Testing Fluid & Lay-up Procedure.
7. SAES-L-105 Piping Material Specification.
8. SAES-L-108 Selection of Valves.
9. SAES-L-109 Selection of Flanges, Stud Bolts and Gasket Piping.
10.SAES-L-110 Limitation of Pipe joint & Component.
11. SAES-L-150 Pressure Testing of Plant Piping & Pipeline.
12.SAES-L-125 Safety Instruction Sheet for Piping & Pipeline.
13.SAES-L-310 Design of Plant Piping.
14.SAEP-351 Bolted Flange Joint Assembly.
15. SAES-L-350 Construction of Plant Piping.
16.SAES-L-410 Design of Pipelines.
17. SAES-L-450 Construction of On-land & Near-shore Pipelines.
18.SAES-W-010 Welding Requirement for Pressure Vessel.
19.SAES-W-011 Welding requirement for On Plot Piping.
20. SAES-W-012 Welding requirement for Pipelines.
21.SAES-W-014 Weld Overlays and Welding of Clad Materials.
22. SAES-H-001 Selection Requirements for Industrial Coating.
23. SAES-H-100 Painting Requirements for Industrial Facilities.
24. SAES-H-101 Approved Protective Coating Systems.
25. SAES-G-005 Centrifugal Pumps.
26. SAES-G-006 Positive Displacement Pumps-Controlled Volume.
27.SAES-D-001 Design Criteria for Pressure Vessel.
28. SAES-M-001 Structural Design Criteria.
29. SAES-B-006 Fireproofing for Plants.
30. ASTM A780 Repair of Damaged and Uncoated Areas on Hot Dip
Galvanized.
31.ASTM A123 Standard Specification for Zinc (Hot Dip Galvanized) Coatings on
Iron and Steel.
32. 12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel.
33. 12-SAMSS-008 Erection of Structural and Miscellaneous Steel.
34. 31-SAMSS-004 Centrifugal Pumps.
35. 31-SAMSS-009 Positive Displacement Pumps-Controlled Volume.
36. 01-SAMSS-017 Auxiliary Piping for Mechanical Equipment.
37.32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers.
38. 04-SAMSS-048 Valve Inspection and Testing Requirements.
39. 32-SAMSS-020 Manufacture of Trays and Packing.
40. 32-SAMSS-022 Manufacture of Components for Flare Systems.
41.31-SAMSS-004 Centrifugal Pumps.
42. 32-SAMSS-004 Manufacture of Pressure Vessel.
43. SAES-A-206 Positive Material Identification.
44. SAES-B-054 Access, Egress & Material Handling for Plant Facilities.
45. SAES-B-053 Mach. Safety Guarding, Elevators, Escalators & Conveyors.
46. SAES-M-001 Structural Design Criteria for Non-Building Structures.
47. SAES-C-001 Process Design of Trays & Packing.
48. SAES-J-200 Pressure…
49. SAES-J-300 Level…
50. SAES-J-400 Temperature….
51. SAES-F-007 System Design Criteria for Flares.
52. SAES-J-600 Pressure Relief Devices.
53. SAES-B-067 Safety Identification & Safety Colors.
54. SAES-N-101 Basic Criteria, Industrial Insulations.
55.SAEP-20 Equipment Inspection Schedule.
56. SAES-M-001 Structural Design Criteria.
57.SAIC-M-2007 Structural Alignment Inspection Checklist.
58. SATR-M-2002 Structural Alignment Test Report.
59. SAIC-M-2009 Structural Bolt Tightening.
60. SATR-W-2008 Weld Summary Report.
61.API-610 Centrifugal Pumps for Petroleum, Heavy Duty Chemicals and Gas
Industry Services.
62. API-614 Lubrication, Shaft Sealing & Control Oil Systems.
63. API-661 Air-Cooled Heat Exchangers & Components.
64. API-675 Positive Displacement Pumps-Controlled Volume.
65. API-686 Recommended Practices for Machinery Installation and
Installation Design.
66. API-1104 Welding of Pipelines and related facilities.
67. API-598 Valve Inspection and testing.
68. API-570 Piping Inspection Code.
69. API-577 Welding Inspection and Metallurgy.
70. API RP-1110 Pressure Testing of Liquid Petroleum Pipeline.
71. ASME-B31.1 Power Piping.
72.ASME-B31.2.
73.ASME-B31.3 Process Piping.
74. ASME-B31.4.
75.ASME-B31.5.
76. ASME-B31.8.
77.ASME-B31.9.
78. ASME-Section VIII Rules for Construction for Pressure Vessels.
CENTRIFUGAL / POSITIVE DISPLACEMENT
PUMP REFERENCE STANDARDS
– SATIP-G-005-01         Centrifugal Pump.
– SATIP-G-006-01         Positive Displacement Pump.
– SATIP-G-115-01         Lubrication, Shaft Sealing & Oil System.

– SAIC-G-2002             Receiving inspection of Centrifugal Pump.

– SAIC-G-2003             Handling, Storage & Inspection of Centrifugal Pump.
– SAIC-G-2004             Inspection of Auxiliary Piping Installation.
– SAIC-G-2005             Inspection of Pump Suction & Discharge Piping Con.
– SAIC-G-2021             Mounting Plate Installation & Leveling for Pumps.
– SAIC-L-2014              Inspection of Bolted Flanges Joint Assembly.
– SAIC-G-2022          Final Pump / Driver Alignment.
– SAIC-G-2007  Final Inspection / Walk through (By Contractor).
– SAES-G-005  Centrifugal Pumps.
– SAES-B-054   Access, Egress & Material Handling of Plant Facility.
– SAES-B-053   Machine Safety Guarding, Elevators, Escalators.
– 31-SAMSS-004 Centrifugal Pumps.
– 31-SAMSS-009  Positive Displacement Pump Controlled Volume.
– 01-SAMSS-017  Auxiliary Piping for Mechanical Equipment.
– Schedule “Q”  Saudi Aramco Quality Requirements.
– API 610  Centrifugal Pumps for Petroleum, Heavy Duty  Chemical and Gas
Industry Services.
– API 675  Positive Displacement Pump Controlled Volume.
COATING REFERENCE STANDARD
SAES-H-001  Selection Requirements for Industrial Coating.
SAES-H-100  Painting Requirements for Industrial Facilities.
SAES-H-101  Approved Protective Coating Systems.

COMPRESSOR REFERENCE STANDARDS
– SATIP-K-402 Centrifugal Gas Compressor.
– SATIP-K-403   Reciprocating Compressor for Process Air & Gas.
– 31-SAMSS-001 Centrifugal Compressor.
– 01-SAMSS-017 Auxiliary Piping for Mechanical Equipment.
– API 617 Centrifugal Compressor for Petroleum, Chemical.
– Schedule Q   Contractor Quality Requirements.
– API 618 Reciprocating Compressor for Petroleum, Chemical.

HEAT EXCHANGER REFERENCE STANDARDS

– SATIP-E-004  Heat Exchanger Installation-Shell & Tube.
– SAES-E-004 Design of Shell & Tube Heat Exchangers.
– 32-SAMSS-007 Manufacture of Shell & Tube Heat Exchanger.
– SAES-H-100  Coating Materials & Application Requirements.

AIR COOLED HEAT EXCHANGER ( FIN FAN

COOLER) REFERENCE STANDARD
– SATIP-E-007-01  Air Cooled Heat Exchanger (Fin Fan Cooler).
– SAES-E-007  Design Criteria of Air Cooled Heat Exchanger.
– 32-SAMSS-011  Manufacture of Air Cooled Heat Exchanger.
– API 614  Lubrication, Shaft Sealing & Control Oil System.
– Schedule Q Contractor Quality Requirements.
– SAES-H-100 Painting Requirements for Industrial Facilities.

ON-PLOT METALLIC PIPING

INSTALLATION REFERENCE STANDARDS
– SATIP-L-351-01 On-Plot Metallic Plant Installation (Excluding Brazed
Piping)
– SAES-L-100  Applicable Code & Standard for Pressure Piping System
– SAES-L-102 Piping Material Specification
– SAES-L-108 Selection of Valve
– SAES-L-109  Selection of Flanges, Stud Bolts and Gasket Piping…
– SAES-L-110 Limitation of Pipe joint & Component
– SAES-L-150 Pressure Testing of Plant Piping & Pipeline
– SAES-L-125 Safety Instruction Sheet for Piping & Pipeline
– SAES-L-310 Design of Plant Piping
– SAES-L-350  Construction of Plant Piping
– SAEP – 351  Bolted Flange Joint Assembly
Aramco QC Questions for all QC Engineers | CBT Test
1. Describe the difference between QA & QC?

Answer: Quality Control is the operational techniques (Inspection, Examination & Testing) that
are used to fulfill requirements for quality. Quality Assurance is the system of action
and planning needed to provide confidence that a Product or Service will satisfy quality
requirements.

2. What do quality system audits evaluate?

Answer: The degree of quality system conformance to established requirements.

3. Saudi Aramco has adopted the basic framework and definitions of the International
Quality Management System Standards ISO-9000 Series. This has been done to provide
universal understanding and improve communication between the COMPANY and
prospective CONTRACTORS who’s Quality Management System is congruent with the
ISO-9000 Series. Describe the basic elements of an ISO 9000 Series Quality Program?

Answer: 

Quality Management & Quality Assurance Standards per ISO-9000.

Quality Management Systems per ISO-9001, 9002, 9003.
Quality Plan Guidelines per ISO 10005.

SCHEDULE “Q” – Is describe a minimum requirement for Contractor Quality System.

ISO 9001 – Quality Management System requirements.
ISO 9000 – Quality Management System Fundamental and Vocabulary.

What is Quality Procedure? It is used to establish instruction for inspection and control of all
construction Activities. This will apply to the incoming materials, intermediary and final works.

What is QA? Quality Assurance system of action and planning needed to provide confidence
that a product or services will satisfy the quality requirements.

What is QC? Quality Control is the operational techniques (Inspection, Examination & Testing)
that are used to fulfill quality requirements.

QUALITY CONTROL PROCEDURE – Is a document that details the specific steps needed to
fulfill the Quality activity in the ITP.
QUALITY CONTROL FORM – Is a writing documentation detailing a specific activity in the
ITP and QC procedure.

A CODE – is a body of laws as of a nation, state or industry group, arranged systematically for
ease of use and reference.
 A STANDARD – is a rule or a basis of comparison in measuring quality, quantity, and content,
relative value and etc.

A SPECIFICATION – is a detailed description of parts or statement of particulars as to actual

or required quality, size and etc.

P&ID – Is a Piping & Instrument diagram show piping layout and detailed notes relating to
piping Instrumentation. This drawing is commonly referred to as the P&ID its object is to
indicate all process service lines, instrument and controls, equipment & data necessary for the
design group. The process flow diagram is the primary source of information for developing the
P&ID.

ARAMCO Quality Codes & Standard References

o ISO 9001 : 2000 Quality Management System.
o SATIP – Saudi Aramco Typical Inspection Plan.
o SAIP – Saudi Aramco Inspection Procedure.
o SAEP – Saudi Aramco Engineering Procedure.
o SAES – Saudi Aramco Engineering Standard.
o SAIR – Saudi Aramco Inspection Requirements.
o SAIC – Saudi Aramco Inspection Check list.
o Saudi Aramco Standard Contractor Schedule “Q” (Project Quality Requirements).
WHAT IS INSPECTION & TEST PLAN (ITP)?

Is all about document based on detailed manufacturing, fabrication and construction program
that identifies each process description, sets out related sequence of activities to be inspected,
examined and tested with relevant approved procedures for particular materials, components and
assembly. It includes identification of required documents, acceptance criteria, which is
responsible, the inspection surveillance and the type and level of inspection including hold,
witness and review points of the contractor, sub-contractor and Saudi Aramco.

INSPECTION & TEST PLAN should include the following information:

o Process descriptions.
o Quality Control Requirements.
o Notification Requirements for Supplier Inspection (min. 10 day calendar days).
o Responsibilities for Inspection / Test.
o Acceptance Criteria.
o Verifying Document.
o Inspection Points (Hold, Witness, Review and Surveillance).
What are Inspection Action Points?
What is Hold Point (H)? 

An inspection point, defined in an appropriate document, beyond which an Activity must not
proceed without the approval of the designated organization or authority.

What is Witness (W) Point? 

An inspection point, defined in an appropriate document, beyond which an Activity can proceed
after notifying the designated organization or authority. Contractor’s QC Inspector has the full
responsibility for performing detailed Inspection during the work activity.

What is Review Point (R)?  

Defined in an appropriate document is the point in which a work activity cannot Proceed without
first ensuring the review and approval of applicable documents Or personnel qualification by a
designated organization or authority

What is Surveillance (S) ?   

QA/QC organization to monitor work in progress without notice from construction organization.

Definitions of Inspection Levels as per (SAER–1972)

– Level 0 – Documentation Requirements only No vendor Inspection required.

– Level 1 – Only Final Inspection is required prior to shipping.

– Level 2 – Includes as minimum, pre-inspection meeting, one or more Un-specified “in
progress” surveillance visits, all witness, hold points, final inspection and release for shipment
– Level 3 – Same as level 2 except that “in progress” surveillance shall be on a regular basis
( daily, weekly or bi-weekly )
– Level 4 – Resident inspector continually monitoring the work

What is Non-Conformance? An Activity does not conform with an International

Code/Standard.

What is NCR? It stands for Non Conformity Report and A record reporting the variation from
the specified requirements.
What is CAR? It stands for Corrective Action Report, It is a record reporting the action take to
eliminate the effect & causes of an existing Non Conformity defect or other undesirable situation
in order to prevent recurrence.
 Piping QC Aramco CBT | Pressure Testing General
Requirements
PRESSURE TESTING REFERENCE STANDARD
o

o SATIP-A-004-02 Hydrostatic Testing of On-Plot Piping.

o SAES-A-004  General Requirements for Pressure Testing.
o SAES-A-007 Hydrostatic Testing Fluid & Lay-up Procedure.
o SAES-L-125 Safety Instruction Sheet for Piping & Pipeline.
o SAES-L-150 Pressure Testing of Plant Piping & Pipelines.
o G.I 0002.102 General Instruction Pressure Testing Safety.
HYDROSTATIC TEST

– A pressure test conducted using water or other approved liquid as the test
medium.

PRE START-UP TEST

– A pressure test to ensure tightness of flanged and threaded joints at the test
Pressure. It is normally conducted before initial start-up, during
commissioning or after T&Is.

PNEUMATIC TEST

– A pressure test conducted using air or other approved gas as the test
medium or in conjunction with liquid.

PRESSURE TEST

– A test conducted to piping or equipment by subjecting it to an internal

pressure using liquid or gas to ensure strength or tightness of the system at
the test pressure.

REVALIDATION TEST

– A pressure test performed to prove the integrity of existing piping or

equipment. This test is administered by the proponent organization.
 SERVICE TEST

– A pressure test conducted at operating pressure using the service fluid.

STRENGTH TEST

– A pressure test at an internal pressure determined in accordance with this

standard and the applicable Code to verify the integrity of the piping systems
or equipment for service at the design pressure.

SYSTEM TEST

– An in-situ pressure test applied to a group of piping and equipment tested as

a system.

PRESSURE TEST PROCEDURE

– Information assembled to ensure all requirements listed in GI-0002.102, All

referenced Saudi Aramco standards and Industrial standards are met.

TIGHTNESS TEST

– A pressure test to ensure tightness of the piping system (i.e., no leaks in the
system) at the test pressure.

SAES-A-004 General Requirements for Pressure Testing

ALL SYSTEM (PIPING & EQUIPMENT) WHILE PRESSURE
TESTING SHALL BE PROTECTED FROM BEING OVER
PRESSURED BY THE FOLLOWING

1. RELIEF VALVE (s) of adequate capacity set to relieve at 5% above the test
pressure shall be installed unless the test pressure is less than 85% SMYS at
which time it can be set at 10%
above the test pressure. Sizing of these relief valves used for testing shall
follow the requirements of API RP 520, Part 1. The relief valve(s) shall be
tested, dated, and tagged within One Week prior to the pressure test for new
construction projects, and within One Month for maintenance operations.
2. In addition to the pressure relieving device, a bleed valve shall be provided to
protect the piping and equipment from over pressure. The bleed valve shall be
readily accessible in case immediate depressurization is required.
3. An isolation valve shall be provided between the pressure testing manifold and
the system being tested. The isolation valve shall be rated for the manifold test
pressure when in the
closed position.
4. PRESSURE GAUGES and pressure recorders shall be calibrated before the
Test. The calibration interval shall not exceed one (1) month. Calibration
certificates shall be made available to Inspection personnel prior to
commencement of the pressure test. Stickers shall be applied indicating the
latest calibration date.
5. All gauges shall have a range such that the test pressure is within 30 to 80% of
the full range.
6. A minimum of two pressure gauges are required for the test system. One
pressure gauge shall be on the test manifold and the other(s) on the test
system. Their accuracy shall be within 5% of one another.
7. When large systems are tested, Inspection personnel will determine the need
for additional gauges.
8. Recording gauges shall be used where it is necessary to keep a permanent
record, e.g., when the test duration exceeds four hours, or otherwise as
required by this standard.
9. PRESSURE TESTING MANIFOLD in the actual system pressure test, it shall
be separately pressure tested to at least 1.2 times the system test pressure but
not less than the discharge pressure of the pump used for the pressure testing.
HYDRO-TEST Package Content Test procedure shall be
available at site all times.
1. Flow chart.
2. Hydro test index.
3. SIS / Test press diagram / legend.
4. Piping plan drawing.
5. P&ID drawing.
6. Isometric drawing.
7. Welding summary report including NDT report & RTFI assessment.
8. Support type & drawing.
9. Valve test certificate.
10.Flange joint inspection report.
11. Internal cleaning & flushing report.
12.Pre-test punch list – punch “A” should be close prior for proceeding test
package review & testing.
13.Reinforcing pad pneumatic test report.
14.Calibration report.
15. Filling & pressurization report.
16.Pressure test report.
17. Lay-up report.
18.Reinstatement.
19.Final inspection report.
20. Coating report.

Hydrostatic Test Procedure and Lay-up

Procedures
This article is about Hydrostatic Test Procedure of Pipeline, Pressure Vessel,
Storage Tanks as per International Standard and Codes (ASME) and what are
testing requirements and what problems can face during testing. You can
extract this article as PDF. You will understand here about hydrostatic test
pressure calculation.

Hydrostatic Test Procedure and Lay-up

Procedures
1.1  Purpose
The purpose of this testing procedure is to provide guidelines to conduct Lay-
up of equipment according with SAES-A-007 (Hydrostatic Testing Fluids and
Lay-up Procedures) in Plants and Refinery Projects. This document is issued
for purpose of the special process  work  procedure of “SCHEDULE “Q”.
Why We Do Hydrostatic Test for Equipment and
Pipeline?
1)    This standard establishes requirements to control corrosion and
microbiological damage after hydrotesting of new, revalidated, and
refurbished equipment when equipment is hydrotested in accordance  with
SAES-A-004,  SAES-L-150 or required by other standards that specially
reference SAES-A-007.

2)   The procedures in this standard are designed to prevent corrosion due to
oxygen (air) ingress and to prevent microbial induced corrosion.  Lay-Up
procedure  shall prevent oxygen  ingress except as specially allowed in this
procedure.

3)   Lay-up Matrix for specific systems is presented in Attachment 1  of this

procedure.  If there is any apparent conflict  between Attachment  1  and the
general requirements in the remainder of the procedure,  Matrix in
Attachment 1 shall govern.

4)    No deviation shall be made from  this procedure without written  approval
from COMPANY. However,  Company and Contractor  can mutually agree to
change the lay-up method, if site condition required modification.

REFERENCE DOCUMENTS

 Project Specifications

Piping Material Specification

Line Designation Table for J10

Procedure for Piping Pressure Test

 2.2     Saudi Aramco Standard
SAEP-327 Disposal of wastewater form  cleaning, flushing and dewatering
pipelines and vessels.

SAES-A-004  General Requirements for Pressure Testing.

SAES-A-007 Hydrostatic Testing Fluids and Lay-Up Procedures.

SAES-L-350  Construction of Plant Piping.

SAIC-A-2018 SA Check List – Test Medium for Hydrostatic Testing & Lay-up

SATR-A-2009 SA Test Report – System  Lay-up Report (Certificate)

SATR-A-2014 SA Test Report – Water  Chemistry Report

SATIP-A-004-001 Pneumatic Pressure Testing.

SATIP-A-004-002 Hydrostatic Testing  of on Plot Piping.

G.1.2.012  Isolation Lock out and Use of Hold Tag

G.1.2.102  Pressure Testing Safety

G.1.2 . 710 Mechanical Completion and Performance Acceptance of Facilities

3. RESPONSIBILITIES
3.1  Site Manager
Site Manager shall responsible for overall management and HSE of all
Construction  and Pre commissioning activities at site including fabrication,
installation and testing.

3.2   Pre-commissioning Manager
1. Responsible for the overall implementation of the work procedure,
coordination with parties involved in the lay-up activities. The Pre-
commissioning Manager will ensure that specified preparatory works  and
associated documentation  are prepared in accordance with this procedure.
2. As for Lay-up after Pressure Test,  Piping manager will  handle it as
construction  activity.
 3.3  QC Manager
Ensure the adequate implementation and application of this procedure 
according to SAUDI ARAMCO  Standards and Specifications,  Applicable
Codes and Manufacturer Recommendations.

3.4   QC Inspector
1. Responsible for witnessing/approval of the activity, to ensure that the in-situ
Layup of piping/equipment is performed  and developed  in an orderly
controlled  manner in compliance with the Saudi Aramco Standards,  Project
Specifications and applicable SATIP/SAIC inspection and test plan.
2. QC Inspector shall be responsible to coordinate the communication way for
the lay-up activities between  CONTRACTOR and COMPANY (PIO and
SAPMT) by issuing RFI.
3. QC Inspector will be responsible for monitoring the compliance of the lay-up
3.5  Pre-commissioning Supervisor
1. The Pre-commissioning Supervisor shall be responsible for executing  the
work  in strict compliance of this procedure, following and controlling the
safety  procedure during the lay-up activities.  Secure  all necessary work
permits prior to carry out the activity.
2. The Pre-commissioning Supervisor shall be responsible for ensuring that
System Lay-up is maintained.
3. As for Lay-up after  Pressure Test, Piping supervisor will handle it as
construction  activity.
4. SAFETY CONSIDERATION DURING
HYDROSTATIC TEST
5. LAY-UP METHOD
Equipment shall be laid-up after hydrostatic test, unless it can be ensured that
it will be returned to service within 30 days from the first introduction  of
hydrostatic test water to the system. Use one of the lay-up methods detailed
below.

1. These methods  shall be applied for piping and equipment which are made of
Carbon Steel, Galvanized Carbon Steel,  Low Alloy Steel, and Stainless Steel,
as per SAES-A-007.
2. At the end of the lay-up, commission and start up heat exchangers within 14
days, and other equipment within 60 days.
5.1   No Lay-up
1. According  to SAES-A-007 Para 7.7, water  shall not require treatment if used
to pressure test completely  internally coated or lined equipment, or systems
entirely fabricated with non metallic materials. No lay-up procedure  is
required for totally  non-metallic systems (e.g.,  PVC or RTR pipe).
2. Regardless of piping material,  “No Lay-up” will be applied to all piping which
is open to the atmosphere such as trim vents and drains, which are categorized
as visual, gravity and service test package.
5.2    Ambient Lay-up
1. Ambient lay-up will be used on services where all of the following conditions
apply:
A. Drains are available at all low points to ensure complete removal of water
B. Corrosion allowance has been provided,
C. Pitting  can be tolerated; and
D. Particulate rust can be tolerated.
2. Water from the system will be removed. For facilities other than pipelines,
drain the system completely, sweep and mop as required to ensure that no
visible traces of water remain.
3. Dewatering condition shall be confirmed with monitoring no more water
coming out from the test package for a minimum ten (10) minutes.
4. After confirming that the test package is drained, ,  the system  will be
protected  to prevent the entry of sand or rainwater.  Holding positive pressure
will not be required for Ambient Lay-up.
5.3  Dry Lay-up

1. Dry lay-up using dew point controlled  air may be performed in systems where
the dew point can be successfully  reached within 1  week. Longer drying
periods using air may contribute to the generation of excessive quantities of
corrosion products in lines. Therefore,  dry lay-up using air is only appropriate
for systems that can be easily dried.  One means to assure effective drying
within the required time is to limit the length of the system being hydrotested
at one time.
2. After  hydrotest, water from the system  shall be removed. For facilities other
than pipelines, the system will be completely drained, sweep  and mop as
required to ensure that no visible traces of water  remain, when applicable.
3. Immediately after  dewatering, the system  will be dried until ensure a dew
point of -1C  or less at all exit points. Drying operation will be done by blowing
dry air through the system  for not less than 12 hours to allow any remaining
moisture to come to equilibrium with the dry air.
4. After  drying operation it will be checked  and ensured that all measurement
locations are at or below the required dew point. In case that a measured dew
point at any one location is above the set limit drying procedure will be
repeated.
5. Dew point temperature  readings at each test location and the pressure of the
line or system at the time of dew point measurement will be recorded.  If
different  to the actual system or line pressure,  the pressure at which the dew
point measurement is made will be recorded.
6. When the required dew point is reached (lower than -1°C),  the system will be
pressurized with dry air to the final lay-up pressure (30 psig) and hold
pressure during bubble test to be done to ensure no leak in the piping system.
7. The  system will be shut in, maintaining and monitoring the pressure during
the lay-up period.
8. Some equipment, such as soft seated valves and control valves will be removed
from the line, prior to hydrotest,  as per SAES-A-004  Para.  8.  However,
remaining equipment must be carefully  dewatered. As the final stage of the
dewatering  process,  remove water from  pipeline valves and all other valves
that may be damaged by trapped hydrotest water by blowing through the top
drain and displacing fluid  out of the bottom of the valve.
5.4  Inert Gas (Nitrogen) Lay up
The way will consist in displacing the hydrostatic test water  by positive
pressure with nitrogen or sweet gas until no water drains out of the system.
Shut in the system under positive pressure until commissioning and start-up.

Oil Lay–up

Lube oil lines are tested  by lube oil as per SAES-A-004 and SAES-L-150. Therefore,  after testing and cleaning,
 system will be left with oil until Commissioning stage, when the oil will be replaced by new brand one.

Special Requirement

1) Utility Systems
1. Utility and potable water  systems shall be tested  in accordance  with SAES-S-
060  or SAES-S-070,  as appropriate.
2. Potable water  systems  shall be tested with fresh  potable water  only
following  the requirements of SAES-S-070,  Paragraph 18 . 2 .  Oxygen
scavengers and biocides shall not be used in potable systems.
2)   Dry Gas and Refined Hydrocarbon  Product Pipelines and
Piping
A. Prevent corrosion during hydrotest and lay-up procedures for sweet sales gas,
ethane, refined products such as gasoline,  kerosene,  diesel,  etcetera,  and
processed   Corrosion  products  and other contaminants introduced during
construction,  hydrotesting, and start-up can create  major problems for many
years.
B. When water is finally removed from  the pipe, either  ai the end of the hyrotest
or at the end of a wet lay-up, the system shall be thoroughly dried. Air drying
shall not be used for pipelines. Air drying may be used for small in-plant
piping systems if drying can be completed in no more than one wee
3)   Plant Piping
A. In general,  new or existing pipework in plants and refineries will be
hydrotested  either on site or in a plant fabrication shop.  Due to the shorter
physical length of this equipment, hydrotest can be effected in a shorter time
than that which would require chemical treatment with oxygen  scavengers or
biocides  per SAES-A-007 5.1, 6.3, or 5.2.2. Therefore,  unless these time limits
are exceeded,  no chemical treatment is required.
B. Due to the complexity of plant construction operations,  often  new plant
pipework  is laid up by drying following  the requirements  of SAES-A-007
Para.  5.2.3 to achieve  a dew point of -1C .  Drying is normally achieved within
a plant using dry air or sometimes nitrogen.
C. Chloride limits for 3xx-series stainless steels must be strictly followed.
D. Water shall not require treatment if used to pressure test completely internally
coated or lined equipment, or systems entirely fabricated with non-metallic
materials. No lay-up procedure is required for totally non-metallic systems
(e.g., PVC pipe).
E. Lube oil systems shall be pressure tested following the requirements of SAES-
L-150. Water shall not be used.
F. Instrument air systems shall be pressure tested following the requirements of
SAES-J-901 and SAES-L-150. Water shall not be used.
G. Boilers shall be laid up per SAEP-1026.
H. For heat exchangers, lay-up shall be required unless start up occurs within 14
days of commencing the hydrostatic test.
4) Stainless Steel Equipment

A. Type 300-series stainless steels shall be tested only with water that has very
low chloride content in order to avoid pitting and stress corrosion cracking.
The maximum allowable chloride concentration is 50 ppm. Verify the quality
of the water following the requirements of SAES-A-007 Para. 4.2.
B. Type-400-series stainless steels are highly prone to atmospheric corrosion.
Type 400 series stainless steel trimmed stainless steel (SS) valves shall be
removed from pipelines before hydrotest. If it impossible to remove such SS
valves from the line, then written hydrotest procedures must be prepared and
approved ahead of time allowing the SS valves to remain in place. When
stainless steel equipment containing any Type-400 series stainless steels is left
in place, it shall be hydrotested in accordance with the requirements of SAES-
A-007 Para. 6.3, 6.4, and 6.5. The hydrotest procedure shall carefully detail
measures prevent corrosion including lay-up of the equipment. Do not use
ambient lay-up for equipment made of 400-series stainless steels.
6. IMPLEMENTATION
6.1 Water Quality
1. Water used for any part of the hydrotesting or subsequent lay-up shall have a
sulphate reducing bacteria (SRB) count of 10³ per ml or less as determined by
the RapidChek II Method or alternative test method approved by
Supervisor, CTU/ME&CCD/CSD. Water that has a higher bacteria count may
be accepted at the discretion of the Concerned authority, after treatment with
biocide and retesting. Measurement of SRB shall be carried out as close as to
the introduction of the water to the system.
2. It will be ensured that the mixing of the waters will not cause scaling if water
used for Hydrotest or subsequent lay-up is coming from more than one
source.
3. Water used for any part of the hydrotesting or subsequent lay-up shall be
clean and free from suspended matter. Suspended matter in the water shall be
extracted, before use, by a filter capable of removing 99% of all particles 53m
(2.1 mil) in diameter and larger, or equivalent to using a 270 mesh wire mesh
screen.
4. See Section 5.7.4}, paragraph “a” for restrictions on the quality of water used
for testing/lay-up austenitic stainless steels. Seawater or high TDS aquifer
water shall not be used for this purpose. The construction contractor shall
keep a permanent written record of the water supplied for testing stainless
steels including a record of tests performed on the water.
5. Potable water systems shall be tested with fresh potable water only following
the requirements of SAES-S-070, Paragraph 18.2. Oxygen scavengers and
biocides shall not be used in potable systems.
6. An approved oxygen scavenger (see Appendix 1) shall be added to the
hydrostatic test water, when the equipment contact time with hydrotest water
may exceed 14 days for carbon steel and low alloy steel equipment or 4 days
for stainless steel equipment. Treat the water before it enters the system.
6.2 Precaution
Special attention shall be paid to the following precautions when lay-up is
performed:

1. A maximum allowable chloride concentration shall be less than 50 ppm for

austenitic stainless steel pipes and piping components in contact with water to
avoid stress corrosion crack. After all the operations, the piping systems will
be completely drained, dried up to having a dew point below -1 °C and
protected against corrosion as per Section 5.7.4).
2. After hydrotest, lines will be carefully drained and air blown using plant air by
connecting hoses to suitable points, as required. After the air blow to a
required dryness, Lay-up procedure will be applied.
3. Suitable measures will be taken to ensure that during drainage water does not
affect/enter to the equipment. Special attention will be paid to equipment
protection and protection measures such as installation of temporary elbows
or hoses at water outlet points, plastic covers on equipment and nozzles shall
be used when required.
4. Systems laid-up with nitrogen (Inert gas lay-up) will be properly identified
and tagged.
5. Access to areas where nitrogen purge is being carried out will be restricted.
6. When working in open areas, close to nitrogen outlet, it is mandatory to
monitor oxygen levels during the work. Check proper functioning of Oxygen
detector.
6.3 Planning
1. Selected Lay-up method shall be indicated in each test package as per stated in
Lay-up Method Matrix (Attachment 1 ).
2. Before starting any hydrotest, lay-up method to be applied shall be approved
and all required material for its execution available.
3. When possible the re-instatement of the system should be done before the
execution of lay-up activity. However, total duration between first
introduction of water and execution of lay-up will not exceed of 30 days for
Carbon steel or 14 days in case of stainless steel.
4. Check/confirm the following items:
o Confirm that handheld oxygen meter or dew point meter is on place as per
needs according to the Lay-up method.
o COMPANY personnel, who will witness the activity, shall be informed 24
hours prior to start up of Lay-up activities by issuing a RFI.
5. Confirm that the normal operation pressure of the system allows to keep the
final positive pressure specified during dry and inert gas lay-up (30 psig). If
normal operation pressure is lower than positive pressure for lay-up, new
value shall be submitted to the COMPANY for their approval.
6. A Cold Work Permit will be issued for lay-up operation according to
CONTRACTOR procedures.
6.4 Site Preparation
1. Components in new piping systems which interfere with filling, venting, or
draining shall not be reinstalled until lay-up is completed or just before
pressurizing the system up to the final positive pressure. These include orifice
plates, flow nozzles, sight glasses, positive displacement and turbine meters
and other in-line equipment.
2. During draining operations, the following actions will be taken when
necessary:
✓ Protections/covers will be used to protect exposed motors, insulation, and
 instruments near the flow outlet.
✓ To direct the outlet flow towards a place where there is no sensitive
equipment.
✓ To change the direction of the flow by rotating an elbow.
✓ To connect a hose pipe at the outlet to drive the flow to a safe location.
✓ To add a dummy spool to extend the outlet further.
✓ On platforms, to protect the equipment and the people on the deck
underneath.
6.5 Work Flow
1. First lay-up will be conducted by the test package wise as the construction
work after the pressure test and reinstatement.
2. System lay-up will be conducted as the pre-commissioning work, once all
related works are completed.
Table 1 – Lay-up Work Flow
 6.6 Post Work
1. Suitable protective measures shall be taken for pipes where ambient lay-up is
applied, to ensure ingress of dirt does not occur.
2. For dry lay-up after System Lay-up, re-measure the dew point at all original
test locations after reaching final lay-up pressure. Check the dew point and
 pressure later than 12 hours after lay-up. If dew point is not higher than -1 °C
at lay-up pressure, check the dew point and pressure after 1 week. After 1
week, it still remain below than -1C at lay-up pressure, check the dew point by
monthly after. (If any dew point reading is found to be higher than -1 °C at the
lay-up pressure, then the entire line must be dried again.)
3. For dry lay-up after System Lay-up, positive pressure of 30 psi g is to be
maintained and monitored throughout the duration of pre-commissioning,
unless the lay-up pressure is no higher than Maximum Allowance Operating
Pressure (MAOP).
4. After lay-up is executed, the corresponding record sheet shall be signed off by
all parties confirming the acceptance of the work. This record will be included
in the corresponding Test Package:
✓ System Lay-up Report (SATR-A-2009)
✓ Water Chemistry Report (SATR-A-2014). If required.