METHOD STATEMENT

MIP6-PI-1302-006
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Contract: 6600044662 (OOK) & 6600044663 (IK)

ARAMCO OVERSEAS COMPANY B.V. & SAUDI ARABIAN OIL
Client’s Name: COMPANY
(SAUDI ARAMCO)
Project Title: MIP PKG06 – ONSHORE OIL FACILITIES PROJECT
Project
TANAJIB OIL PLANT, KINGDOM OF SAUDI ARABIA
Location:

REV A1 A2 A3
Sig. Sig. Sig.
DATE 03.SEP.20 12.OCT20 29.JAN.21
J.W. KANG J.W. KANG J.W. KANG
ORIG. BY PIPING J.W.KANG PIPING J.W.KANG PIPING
MANAGER MANAGER MANAGER
QA
B.K. ROH B.K. ROH B.K. ROH
REVIEW QA MANAGER
B.K.ROH
QA MANAGER
B.K.ROH
QA MANAGER
BY
J.Y. LIM J.Y. LIM J.Y. LIM
APP. BY PROJECT J.Y.LIM PROJECT J.Y.LIM PROJECT
MANAGER MANAGER MANAGER

CLIENT
APP

Issue History

1. Rev 2. Reason for Issue

3. A1 4. Issued for Review
5. A2 6. Issued for Approval
7. A3 8. Issued for Approval
9. 10.
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TABLE OF CONTENTS

1. PURPOSE ………………………………………………………………………………………… 3
2. REFERENCES ……………………………………………...................................................... 3
3. RESPONSIBILITY…………………………………………..................................................... 4
4. RESOURCES ……………………………………………….................................................... 5
5. MATERIAL SELECTION ……………………………………………………………………...... 5
6. FABRICATION …………………………………………………………………………………... 10
7. WELDING & WELDING RECORD ……………………………………………………………. 13
8. POST WELD HEAT TREATMENT ND WELD HARDNESS TESTING …………………… 14
9. FINAL CHECK AND TOLERANCES …………………………………………………............ 15
10. FIELD INSTALLATION ………………………………………………………………………... 16
11. NON-DESTRUCTIVE TESTING …………………………………………………………....... 24
12. PAINTING …………………………………………………………………………………......... 24
13. TEST PACKAGE ………………………………………………………………………………. 24
14. REINSTATEMENT ……………………………………………………………………………... 24
15. CONTRACTOR’S DOCUMENT AND REPORT ………………………………………….... 25
16. ATTACHMENT …..……………………………………………………………………………... 25

1. PURPOSE
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1.1 This procedure is provided to describe the instruction for general requirements of metallic
piping works including fabrication, installation, pressure test and reinstatement in MIP PKG 06
– ONSHORE OIL FACILITIES PROJECT
1.2 This procedure shall be applied to metallic piping works according to the codes and
construction specifications described in paragraph 2.0.
1.3 These Procedures have to follow the applicable Project Specification listed in paragraph 2.3.

2. REFERENCES

2.1 SAUDI ARAMCO REFERENCES

2.1.1 SAES-A-004 General Requirements for Pressure Testing

2.1.2 SAES-A-206 Positive Material Identification
2.1.3 SAES-L-105 Piping Line Classes
2.1.4 SAES-L-108 Selection of Valves
2.1.5 SAES-L-132 Materials Selection for Pipelines, Piping and Process Equipment
2.1.6 SAES-L-136 Pipe, Flange, and Fitting Material Requirements
2.1.7 SAES-L-150 Pressure Testing of Plant Piping and Pipelines
2.1.8 SAES-L-350 Construction of Plant Piping
2.1.9 SAES-L-125 Safety Instruction Sheet for Piping and Pipelines
2.1.10 SAES-L-110 Limitations on Piping Joints and Components
2.1.11 SAES-S-070 Installation of Utility Piping Systems
2.1.12 SAES-W-011 Welding Requirements for On-Plot Piping
2.1.13 SAEP-324 Certification Review and Registration of Project Welders
2.1.14 SAEP-351 Bolted Flange Joints Assembly
2.1.15 SAEP-352 Welding Procedures Review and Approval
2.1.16 SAEP-1142 Qualification of Non-SA NDT Personnel
2.1.17 SAEP-1160 Tracking and Reporting of Welding, NDT and Pressure Testing For
Capital Projects
2.1.18 01-SAMSS-010 Fabricated Steel Piping
2.1.19 01-SAMSS-035 API Line Pipe
2.1.20 02-SAMSS-005 Butt Welding Pipe Fittings
2.1.21 02-SAMSS-011 Forged Steel and Alloy Flanges
2.1.22 04-SAMSS-001 Gate Valves
2.1.23 04-SAMSS-002 Steel Globe Valves – Flange and Butt-welding Ends
2.1.24 04-SAMSS-003 Additional Requirements for Low Temperature Valves
2.1.25 04-SAMSS-005 Check Valves, Swing Type
2.1.26 04-SAMSS-035 General Requirements for Valves
2.1.27 04-SAMSS-051 Ball Valves, API Spec 6D
2.1.28 PIP PNSC 0001 Fabrication and Examination Specification for ASME B
31.3 Metallic Piping
2.1.29 PIP PNSC 0011 Installation of ASME B31.3 Metallic Piping
2.1.30 PIP PNSC 0021 Leak Testing of Pipe Systems
2.1.31 PIP PNE 00012 Piping Examination and Leak Test Guide

2.2 INDUSTRY CODES AND STANDARDS

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2.2.1 ASME B 31. 3 Process Piping
2.2.2 ASME B 1.20.1 Pipe Threads, General Purpose
2.2.3 ASME B 16.25 Butt Welding Ends
2.2.4 ASME Section Ⅰ Power Boilers
2.2.5 ASME Section Ⅴ Non-Destructive Examination
2.2.6 ASME Section Ⅷ Pressure Vessels
2.2.7 ASME Section Ⅸ Welding and Brazing Qualifications
2.2.8 ASTM E165 Liquid Penetrate Examination
2.2.9 PFI Recommend Practice for Piping Fabrication Institute
2.2.10 ASME D1.1 Structure Welding Code

2.3 PROJECT SPECIFICATION AND PROCEDURE

2.3.1 M99-L-CE-019945 Piping Material Specification
2.3.2 MIP6-PI-1302-002 TIE-IN Procedure for Piping
2.3.3 MIP6-PM-1340-006 Receiving Inspection
2.3.4 MIP6-PM-4401-002 Color Coding for Material Identification
2.3.5 MIP6-PM-1332-001 Storage, Handling and Preservation

3. RESPONSIBILITY

3.1 CONTRACTOR Engineering Manager shall be responsible for the issuing of IFC drawing and
ASB (As Built) drawings when the line is completely installed.

3.2 CONTRACTOR Field Engineer is responsible for the selection and preparation of the
isometric drawings/ spool drawings for shop fabrication and field installation. He shall be, also
responsible to select the material required for piping shop fabrication and field installation.

3.3 CONTRACTOR Site Discipline Manager shall be responsible for piping shop fabrication work
and field installation work.

3.4 CONTRACTOR QC Manager shall be responsible for all quality control and documentation to
be done during piping shop fabrication and field installation activities.

3.5 CONTRACTOR Site Manager shall be responsible for fulfilment of this procedure.

3.6 QC Inspector shall be responsible for inspection and monitoring of the work and to ensure
that the work is performed and properly documented in accordance with approved ITP’s,
Method Statement, and Project requirements.

3.7 Piping Supervisor shall be responsible to manage the execution/supervision of piping works
in a safe manner, conduct the daily Toolbox meeting before starting the work. Shall ensure the
availability of the approved HSE relevant documents (MS, JHA and Work Permit).

3.8 Welding Foreman is solely responsible to ensure that all welding works are in conformance
with applicable codes and standards, specifications and approved welding procedures.

3.9 HSE Officer shall be present on site at all times during construction activities.
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4. RESOURCES

4.1 Tools & Equipment

4.1.1 Ball Hammer
4.1.2 Wrenches
4.1.3 Magnetic Spirit Level
4.1.4 Fillet Gauges
4.1.5 Dial Indicator
4.1.6 Pipe Jack Stands
4.1.7 Chain Block/Puller
4.1.8 Pulley
4.1.9 Cable
4.1.10 Flange Jack
4.1.11 Feeler Gauge
4.1.12 Bevel Gauge
4.1.13 T-Square
4.1.14 Straight Edge
4.1.15 Hi-Lo Gauge
4.1.16 Wrap Around
4.1.17 Crane
4.1.18 Boom Truck
4.1.19 Trailer
4.1.20 Forklift
4.1.21 Welding Machine
4.1.22 Hand Grinder
4.1.23 Pencil Grinder
4.1.24 Cutting Outfit
4.1.25 Pipe Roller
4.1.26 Generator Set
4.1.27 Drip Tray/Secondary Containment for all stationary equipment

5. MATERIAL SELECTION

5.1 Material

5.1.1 Piping materials specification shows on the piping isometric drawings. Materials not
identified on drawings or isometrics shall be in accordance with SAES-L-105 piping
material specification.

5.1.2 All piping and fittings shall have the material specification and grade stamped, stenciled,
or otherwise clearly marked with permanent marking method.

5.1.3 All pipes, fittings, flanges, and gaskets material shall be sourced from approved
manufacturers in accordance with SAES-L-132 and SAES-L-136. This should confirm
through proper material identifications and certifications.
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5.1.4 Valves shall be sourced from approved manufacturers in accordance with SAES-L-108.
This should confirm through proper material identifications and certifications.

5.2 Receiving

5.2.1 Receiving is defined as taking delivery of piping materials from the warehouse with
relevant issue-slip.

5.2.2 Rejected materials during inspection by Contractor QC inspector, shall be handled as

per MIP6-PM-1340-006

5.3 Transportation, Handling and Storage

5.3.1 All material shall be handled with care during fabrication and installation to prevent
damage as per SAES-L-350 para 7,8.

5.3.2 Special care shall be taken to protected flange faces during piping handling operations.
For protection shall be used a plastic boards, aluminum sheet board, etc.

5.3.3 Lifting shall be done by using contractor rigger and furnished lifting equipment. Lifting
lugs shall be visually inspected for cracks, deformation, and/or any damage before to
use.

5.3.4 All transport on trucks, trailers, dollies, or skids shall be done with the equipment
properly secured to the carrier. Tie-downs shall be capable of counteracting forces equal
to the transported weight.

5.3.5 Transports parked or left unattended shall be blocked in such a manner that movement
will be prevented, and obstruction barriers shall be placed to the front and rear as a
warning to traffic.

5.3.6 For stainless steel piping material, the handling shall be done as following specified:

a. A separate storage area for stainless steel piping material shall be provided on work

shop and shall be segregated from other materials.

5.3.7 For lifting shall be used a nylon sling or stainless steel wire slings.

5.3.8 Fabricated spool shall be transported to the spool storage yard by trailer or cargo truck
and they shall be arranged on the basis of each material, area & system at the spool
storage yard, which prepared by Contractor before work start.

5.3.9 Storage yard defines act of handling materials at the construction site or in an area other
than its permanent location in the plant.

5.3.10 When the spools are moved to storage yard, spool controller shall record and maintain
all the information including present location for each spool. Storage spool location map
shall be done.
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5.3.11 Storage yard shall be organized to maintain and handle simply all the fabricated spools
with proper handling equipment (Hydraulic crane, Folk lift & Vehicles and etc).
5.3.12 Contractor shall prepare timber for spool storage. The ring joint and raised face flange
shall be protected from other items with wooden board, plastic boards or plugs etc.

5.3.13 Piping materials will be withdrawn from the storage areas as the installation
requirements occur.

5.3.14 S/S, LTCS, ALLOY and C/S materials shall be stored separately.

5.3.15 Residual piping material, especially short-piece pipe shall be stored at the designated
area with material heat number. All scraps shall be temporary kept in same place and
segregated by type of materials, for future weighting and final reconciliation.

5.3.16 If necessary, the Contractor’s spool control team shall bind a color ribbon on the
fabricated pipe spool which is already identification marked or attached with label sticker
for easy spool selection and classification.

5.3.17 Stacking of coated pipe shall be made in manner to avoid damage to pipes or coating.
Refer to SAES-H-200.

5.3.18 Lined and coated pipe 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 para. 2.

5.4 Material Verification

5.4.1 Before shop fabrication, the piping materials shall be checked as following:
a. Transit damages
b. Dust on pipe, conditions of fitting and flanges

c. Corrosion presence
d. Material shortage
e. The stock code number of the piping material shall be checked against the material list
on the isometric drawing and/or on the available material voucher

5.5 Material Identification

5.5.1 Color Coding

The Identification color coding of piping materials shall be applied in accordance with MIP6-
PM-4401-002 Color Coding for Material Identification and SAES-A-206 para14 marking &
color cording.

a. The color coding system for material identification is intended to help prevent
fabricators from using incorrect alloy material. The principal purpose of color coding is
visual identification during storage and after the components has been cut for
fabrication.
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b. Color coding is not a substitute for the PMI testing or permanent marking required by
ASTM or other standards, and shall not to be removed by sand blasting or covered by
painting until there is proper transfer of identification number to the cut pieces to
maintain traceability.

c. Pipe shall be easily traceable before, during and after sand blasting and painting.
Pipes shall be segregated at all time, easily traced, and marked according to SAES-A-
206, PFI ES-22.

d. Valves, flanges, and fittings do not require color coding if their components are
permanently stamped or tagged by the manufacturer. If the materials are not easily
legible, valves, flanges, and fittings shall be coded with a stripe of 5mm minimum
width. The color coding on valves should indicate the valve body material.

5.5.2 Marking

a. Each piece shall be plainly marked with the piece number, using paint. After
application of primer, or rust prevention on carbon steel piping, Identification marks on
piping material shall be maintained until piping is fabricated.

b. Marking paint or ink for stainless steel and nickel alloy shall contain low chlorides
marker or metal salts that could cause corrosive attack on the piping.

c. The use of adhesive labels on stainless steel or nickel alloy piping requires a
protective barrier of paint containing no chlorides, metals or metal salts or the use of a
chloride free adhesive.

d. All piping spools shall be marked by proper method, which does not result in harmful
contamination or sharp discontinuities and will identify the material until it is installed.

5.6 Traceability of Material Identification

5.6.1 Identification marks on piping material shall be maintained until the end of fabrication.

5.6.2 During fabrication stage the heat number of parent pipe shall be transferred to all cut
pieces by waterproof marker. These markings shall be at the pipe ends and shall be
easily identifiable.

5.6.3 If identification marks are obliterated, Contractor shall rewrite these identification marks.

5.6.4 For field installation directly without any fabrication, sequence shall be as follow.

5.6.5 The identification methods of piping materials shall be applied in accordance with MIP6-
PM-1332-001 Storage, Handling and Preservation

5.6.6 For Nominal Pipe Size (NPS) 4 inches and over: material specification, heat number and
item codes shall be transferred to inside or outside of both pipe ends by waterproof
marker.
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5.6.7 For NPS less than 4 Inches: material specification, heat number and item code shall be
transferred to outside of both pipe ends by waterproof marker.

5.7 Traceability of Spool Identification

5.7.1 The size of identification lettering shall be sufficiently large so that finding is easily
achieved.

5.7.2 For shop fabrication, color marked pipe piece shall be fabricated based on spool drawing
at shop and sent to painting shop for painting. One aluminum tag bound on spool with
wire and identification marks at one foot from weld joint for spool number identification
shall be checked before sending it out to painting from fabrication shop

6. FABRICATION

6.1 Fabrication and Installation Sequence

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6.1.1 In respect of steel contamination, connection point to be welded on site shall be taped at
least minimum 1 (one) inch prior to painting application after completion of blasting.
Inside color coding of pipes are to be carried out immediately for the purpose of
distinguish the identification immersion of paint oxide into the pipe surface in the stage of
welding activity and stencil to be made on appearance with appropriate depth after
blasting.

6.2 Cutting and Beveling

6.2.1 No flame cutting is allowed for austenitic stainless steel materials. For other materials,
both mechanical and flame cutting methods may be utilized. Contractor will use gas
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cutting machine for non-galvanized carbon steel materials. The cutting flame shall be so
adjusted and manipulated as to avoid cutting beyond the prescribed lines. The thermal
cutting ends shall be ground to bright metal to ensure complete removal of surface
contamination. The roughness of gas cut surfaces and occasional notches on edges
shall be removed by machining or grinding. Cut surfaces and edges shall be left free of
slag.

6.2.2 Cutting shall be performed perpendicularly to the piping component centerline unless
otherwise indicated on the drawings. Cutting shall be made with suitable allowance
taken into account for shape of connections and shrinkage due to cutting and welding.

6.2.3 Contours of all weld end preparation shall be smooth without any rough edges.

6.2.4 Before cutting, suitable material traceability and mark-up of cutting limits shall be done
on each part of materials to be cut.

6.2.5 Special care shall be taken to remove internal burrs resulting from cutting, especially on
pipes equal to or less than 2 inches in diameter.

6.2.6 End Preparation (Bevel) should be applied in accordance with ASME B31.3

6.2.7 Bevel angle should be 37.5 degree with a tolerance of ± 2.5 degree for 6mm to 22mm wall
thickness.

6.3 Cleaning

6.3.1 Oil, moisture, rust, scale, sand, paint, metallic coatings (e. g., zinc), or other foreign
matter shall be removed from the weld surface and at least 25mm (1 inch) of adjacent
base metal prior to welding, including any such coatings on temporary attachments or
supports.

6.3.2 Each welding pass shall be thoroughly cleaned and slug or other foreign matter removed
before the next pass is deposited.

6.3.3 All slug, flux, and spatter shall be removed from the completed weld and surrounding
area.

6.3.4 Stainless steel and nonferrous materials shall be cleaned with grinding wheels or
stainless steel brushes not previously used on other materials.

6.3.5 Cleaning procedure shall be in accordance with SAES-L-350, para15 Prior to

Installation, During Assembly and Erection, Chemical or Vapour Phase or Form cleaning.

6.4 Alignment

6.4.1 After end preparation, the alignment, fit-up and tack weld activities shall be carried out
for the purpose of exact pipe spool fabrication.
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6.4.2 Parts that are to be joined by welding may be fitted, aligned and retained in position
during the welding operation by using of bars, jacks, clamps or temporary attachments in
order to avoid deformation and minimize strains during tack.

6.4.3 Longitudinal weld ID surface of components at ends to be joined in girth or miter groove
welds, shall be aligned within WPS dimensional limit and the engineering design.

6.4.4 Internal misalignment of butt joints shall not exceed 3mm, Internal tapering in
accordance with ASME B 31.3 by machining, back welding, or a combination may be
used to correct the misalignment.

6.4.5 End preparation and alignment shall be applied in accordance with ASME B31.3-
para328.4.2, para328.4.3.

6.4.6 The maximum tolerance for flanges alignment, flattening of bends, flange bolt holes and
other applicable tolerances shall follow SAES-L-350, para9.

6.5 Bending and Forming

6.5.1 Pipe may be bent and components may be formed by any hot or cold method which is
suitable for the material, the fluid service, and the severity of the bending or forming
process. The finished surface shall be free of cracks and substantially free from bucking.
Thickness after bending or forming shall be not less than that required by the design.

6.5.2 Cold Bending

a. Cold bends is not permitted for in-plant piping, 01-SAMSS-010 para7.2

6.5.3 Induction Bends

a. Induction bends shall meet the requirements of the ASME B 31.3, para332. Induction
bending done below the upper transformation temperature shall meet the Cord
requirements for cold bending.

6.5.4 Bending Tolerances

a. Unless otherwise specified on the drawings, tolerances for dimensions of pipe bends
shall be in accordance with PFI standard ES-24.

6.6 Branch Connections

6.6.1 Branch connections shall confirm to SAES-L-110-para13-Branch connection fittings and

para13.1.1 chart 1. Unless otherwise specified, welded branch connections shall be
accordance with ASME B 31.3 Para 328.5.4
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6.6.2 Unreinforced Stub-Ins

a. Unless otherwise specified, welding shall be in accordance with ASME B 31.3. Fig328.
5.4D (2).

6.6.3 Reinforced Stub-Ins

a. Reinforcing pads shall be of the same nominal composition and properties as the
header (run) pipe. Each pad, or separately welded portion of pad, shall have a 1/4 in.
(6mm) diameter vent hole drilled prior to installation of the pad. All required
examinations and repairs shall be completed and approved before reinforcing pads
are welded onto the pipe.

6.7 Machined Surfaces

6.7.1 Machined surfaces, such as flange faces, shall be protected from damage and
deterioration during all operations. Damaged machine surfaces shall be repaired, or the
component shall be replaced.

7. WELDING & WELDING RECORD

7.1 Welding shall be performed in accordance with approved WPS, Welding Process Control

Procedure and SAES-W-011 Welding requirements for on-plot piping

7.2 When seam-welded are joined by butt welding, Preferably the distance (circumferential offset)

Between longitudinal weld of adjacent pipe joints shall be 90 degrees apart or it should be

Positioned at least minimum 30 degrees apart. The position of the longitudinal weld shall be

Indicated on spool erection drawing and spool piece drawing.

7.3 The minimum distance between parallel butt welds shall be 20MM or 3 times wall thickness of

the joint, whichever higher.

7.4 Assignment of welding joint No. shall be followed as per SAEP-1160 para 6.2

7.5 Preheat

7.5.1 Preheat shall be in accordance with ASME B31.3 and SAES-W-011-para12

7.5.2 The pre-heat shall be specified in the approved welding procedure

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7.5.3 If a weld joint is wet or has surface moisture condensation, it shall be dried by

heating

for a distance of 100mm from the weld joint and shall be warm to the hand before

welding unless a greater preheat temperature is required.

7.5.4 Temperature-indicating crayons, thermocouples, or calibrated contact pyrometers

shall

be used to measure preheat and inter pass temperatures. Temperature-indicating

crayons shall not be used for any weld joint that is to be coated or that will have a heat

shrink sleeve installed on it.

7.5.5 The preheat temperature shall be established over minimum distance of 75mm on

each side of weld.

7.5.6 If the wall thickness exceeds 25mm and preheating is to be done from the same side

as the welding, then the heat source shall be removed for 1 minute to allow for

temperature equalization prior to measuring the temperature.

7.5.7 Unless specified otherwise, the maximum inter pass temperature shall be 177°C for

P-No.8, P-No.3X and P-No.4X materials and 315°C for P-1, P-3, P-4 and P-5 steels

7.6 Daily welding inspection report shall be prepared by Qualified Welding Inspector as per the

approved inspection format, through PICS (Piping Integrated Control System).

8. POST WELD HEAT TREATMENT AND WELD HARDNESS TESTING

8.1 Post Weld Heat Treatment (PWHT)

8.1.1 PWHT shall be in accordance with approved P.W.H.T procedure and SAES-W-011
para13 - post weld heat treatment.

8.2 Weld Hardness Testing

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8.2.1 Testing shall be in accordance with NACE RP0472 and the requirements listed below.
Exemptions with respect to welding process and consumables are not allowed. The
testing guidelines in Appendix A of NACE RP0472 shall be mandatory. Readings in the
heat-affected zone shall be conducted if specified by the applicable Code or Standard.

8.2.2 Production Hardness testing of welds shall be performed as required by ASME B31.3

8.2.3 Production hardness testing of welds in P-No 1 material in sour or PWHT service shall
also be performed. The maximum allowed hardness is 200 BHN.

8.2.4 If any reading exceeds the specified limit by no more than 10 BHN, then a minimum of
three (3) additional indentations shall be made near the original high reading. If all three
(3) retests are below the specified limits, then the joint is acceptable. If any of the retest
readings are found to exceed the specified limits, then the weld shall be considered
unacceptable.

8.2.5 If any welds are found to be unacceptable, then two additional welds from the same lot
shall be tested. If more than one weld in a lot is found to be unacceptable, then all welds
in that lot shall be tested.

8.2.6 Weld Hardness Testing

9. FINAL CHECK AND TOLERANCES

9.1 After completion of spool fabrication, Contractor field engineer shall check all kinds of spool
information (material traceability, welding joint mark, welder qualified number, spool number,
etc.)

9.2 Final dimension, orientation, cleanliness and end protection shall be checked.

9.3 All piping and fittings after fabrication shall be cleaned thoroughly with compressed air and/or
rotary wire brushes to remove all sand, loose rust and other foreign matter.

9.4 Protection cover such as plastic cap, wood cap etc. shall be protected the pipe end flange
face.

9.5 Spool inspection

9.5.1 Contractor Q/C engineer shall inspect spool status before transport to spool stock yard
area for the following items.

a. Spool dimension check.

b. Special identification pertaining line number and spool number, etc. shall be done.
c. Color coding and trace-ability check.
d. NDT and PWHT completion status check.

9.6 Tolerances
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9.6.1 Unless shown otherwise on the drawings, tolerances for dimensions of fabricated pipe
sections shall be in accordance with 01-SAMSS-010-Fabricated carbon steel piping and
PFI standard ES-3.

10. FIELD INSTALLATION

10.1 Materials

10.1.1 Piping materials specification shows on the piping isometric drawings. Materials not
identified on drawings or isometrics shall be in accordance with SAES-L-105 piping
material specification.

10.1.2 Material Identification

a. Before cutting, suitable identification markings, including at least grade of steel and
heat numbers shall be produced on each of the cut part of materials.
b. All welds shall be permanently marked with identification symbol of welder or welding
operator

10.2 Material Storage and Handling

10.2.1 Material storage and handling shall be in accordance with SAES-L-350 construction of
plant piping para-7-storage and para-8-handing.

10.2.2 During the transportation of finished products to the storage area, all necessary
precautions shall be taken so as to avoid any deterioration.

10.2.3 All materials shall be stored on pallets or timber blocking, off the ground and above level
of standing water.

10.2.4 Piping components and piping spools shall be stored and handled in such a manner as
to avoid damage or mixing of material types and grades.

10.2.5 Stainless steel piping material shall be stored in separate place from carbon steel piping
material store and no direct contact of stainless steel with carbon steel shall be allowed.

10.2.6 Pipe and fitting ends shall be capped to prevent ingress of water and any foreign matter.

10.2.7 Threaded ends shall be plugged and sealed with tape.

10.2.8 Flange raise face shall be covered from damage by tape or plywood.

10.2.9 For painted spools and pipes, lifting shall be done by sling belt.

10.3 Assembly
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10.3.1 Threaded Joints

a. Threads shall conform to the requirements of ASME B1.20.1 and SAES-L-110-para7-

threaded joints.

b. Pipe ends shall be reamed clean after threading.

c. Thread joint sealant shall be applied to the male ends only and in a manner that will
prevent the compound from reaching the interior of the pipe. Manufacturer’s
instructions shall be followed.

d. Use of PTFE tape shall be followed as per SAES-L-110 para 9.5

e. Unless otherwise specified, thread joint sealant shall be PTFE anaerobic sealing
compound or PTFE tape.

f. Unless otherwise specified, no threaded joints shall be seal welded.

g. Thread joint seal weld shall be followed as per SAES-W-011 para 11.

h. Seal weld shall be followed as per SAES-L-110 if seal weld is not subject to weld.

i. If seal welds are specified, threads shall be free of dirt, grease, and thread
compounds.

10.3.2 Flanged Joints

a. Flange Joints Assembly shall confirm to SAEP-351-Bolted flange joints assembly

b. Pre-Assembly Inspection

1) The gasket shall be verified for correct type, rating, dimension and compatibility with
the flange facing. Also, it shall be free from any damage particularly in the seating
element. Ensure that spiral wound gaskets are stored flat especially for large sizes,
24 inches and larger.

2) The flange facing, particularly the seating area, shall be visually examined for
cleanliness and ensure that no damage, such as scratches exist.

3) For ring joint type flanges, the ring and the ring groove shall be free of damage and
dirt.

4) Bolts, nuts and washers shall be visually checked for proper size, grade, and
dimension and for any physical damage to shanks or threads which would affect the
bolts and nuts material for the service temperature and compatibility with the flange
material.

5) Verify that proper lubricant is used.

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6) Tightening tool shall be checked for adequacy, performance and calibration, if
required.

7) Verify that lubricant is not used no the gasket seating area.

8) Verity that flange shielding is installed, if required.

c. Bolting

1) Flange bolts and studs shall be long enough to penetrate completely through the
nuts, but shall not protrude more than one-bolt diameter.

2) Extra bolt length is required for bolt tensioners.

3) Bolting shall be uniformly tightened by a series of crossovers to assure uniform

loading of the gasket without over-stressing the bolts or flanges.

4) In assembling flanged joints in which the mechanical properties of one flange differ
widely from those of the other (e.g., a steel flange against a cast iron, lined, or
plastic flange), special care shall be used in tightening to the minimum torque
necessary to seat the gasket.

5) Bolts, nut faces, and nut bearing surfaces shall be lubricated before installation.

d. Gaskets

1) Gasket shall confirm to SAES-L-109 -para12- Gaskets.

2) The correct gasket shall be properly seated (only one gasket in any joint).

3) Unless specified by the Company requirements, gasket compounds shall not be

used.

4) A spiral wound gasket shall be compressed until the raised face of each flange
contacts the gauging ring all the way around.

5) Once compressed, a gasket shall not be reused.

6) All gaskets are required to have colored tags that protruded out of the flange to
differentiate between the types of rating. The colored tag on each gasket will allow
easy verification of proper gasket type after installation. Benefits of using the
modified gaskets include allowing easy verification of gasket type after installation
and enhanced piping installation and hydro testing activities and it increased quality
assurance and plant safety.
7) All temporary gaskets to be used for hydro test shall be marked with another
indication and color coding method different from original color coding. (e.g. other
color mark + original color coding)
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e. Electric Isolation Kits

1) Electrical isolation kits, if specified, shall be installed after pressure testing.

2) Care shall be taken not to damage the bolt sleeves and gasket.

3) Welding and other ground leads shall not be installed such that the electrical current
flow is through isolated flanges.

4) A continuity checks to verify isolation shall be performed.

10.3.3 Valves

a. Valves shall confirm to 04-SAMSS-035-General requirements for valves.

b. Valve manufacturer’s installation instructions, including bolt torque, shall be followed.

c. Valve handles shall be oriented as shown on the drawing, vertically if not shown
(unless in a vertical line).

d. Handle shall be modified if required to operate the valve.

e. Check, globe, butterfly, and other valves that require specific orientation shall be
installed as shown on the drawing.

f. Wafer body valves shall be centered in the pipeline.

g. Welded type valves shall be half open during welding & PWHT, but not fully opened.
Flange Control valves, ball valves and other soft seated valves shall be remove before
PWHT and line flushing operations.

10.4 Installation

10.4.1 General

a. All construction and installation works shall be executed according to design drawings,
applicable code, standard, project specifications, referenced procedures and general
practice for above ground works.

b. All welding work shall be performed in accordance with approved welding procedure
specification (WPS), and by qualified welder/ welding machine operator.

c. Modification to pipe routing may be necessary to avoid interference. Details of all

modifications shall be reflected on “As-Built” record drawings.

d. Prior to erection, the interior of all piping components shall be thoroughly cleaned of
loose scale, sand blasting grits or sand and all other foreign matter by appropriate
method.
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e. Rigging of pipe components shall be performed in a good manner that will not cause
any damage to the surface of the components.

f. Prior to the assembly of the component parts of the piping system, each prefabricated
piece, straight length of pipe or fitting shall be visually checked for dirt, rubbish,
grease, loose scale, etc., and cleaned when necessary.

g. Orifice plates rupture discs and permanent pressure gauges shall not be installed until
the pressure test is completed.

h. Piping shall be installed in a manner that resultant forces on the equipment will be kept
to minimum and particular care shall be taken at connection joint of pump, compressor
and other mechanical equipment at which piping resultant forces could cause
misalignment.

i. Straight run pipe shall not be pulled through the pipe racks and pipe sleeper.

j. All piping openings shall be sealed before, during and after erection to prevent the
ingress of moisture and foreign matter. Flanged or threaded ends shall be sealed with
tape, plastic cover or plywood, etc. This also includes open pipe ends of piping being
erected in pipe rack or equipment in the plant.

10.4.2 Piping Installation on the Pipe Rack and Sleeper Way

a. Pipe racks and sleeper way installation shall confirm to SAES-L-310-para12-Lines

spacing requirements/para14-Pipe support design/para15-Anchors and
guides/para16-Non-pressured welded attachment.

b. Survey the pipe rack/ Sleeper way level to calculate shim thickness for line levelling.

c. Mark-up on the pipe rack/ sleeper way the line position as per engineering
coordinates.

d. Lift spools on pipe rack/ sleeper way and lay on marked position.

e. If tie-in alignment with outside pipe rack piping is required, coordination of piping laying
sequence with other working team will be necessary for proper fit-up.

f. For installation of spool line, have to check levels of tie-in points (both, high and low).
The line slope shall be given between these two points. Slope is obtained by different
rack level, shoe height and/or shim thickness.

g. Header line shall be installed and aligned prior to the branch line installation
commencement.

10.4.3 Alignment

a. Piping shall be properly anchored and guided to make proper alignment

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b. Any distortion of piping to bring the piping into alignment for joint assembly that
introduces a detrimental strain in equipment or piping components shall be prohibited.

c. Heating can be used to correct piping misalignment in ferrite materials approval by

company, if necessary.

10.4.4 Equipment Connections

a. Equipment manufacturer’s limitations on piping end reactions shall be followed in

making equipment connections.

b. Pump and compressor piping shall be installed up to a break point between the
nearest pipe support and the equipment.

c. Final tie-in weld for alignment with equipment nozzle shall be done after initial
alignment and grouting the base-frame of equipment.

d. Align equipment nozzle flange and spool flange within acceptable tolerance. To tie-in
weld when alignment is within acceptable range. Continuous gap checking shall be
done during welding.

e. Final bolt tightening of piping flange with equipment nozzle flange shall be done after
piping pressure test checking parallelism of the alignment.

10.4.5 Supports, Anchors, and Other Restraints

a. Permanent supports, anchors and other restraints, including supplementary structural

steel as required for supports shall be erected.

b. Type and spacing of supports indicated on the drawings shall be used.

c. Pipe shall not be visibly sagged and shall be braced to avoid excessive sway, as
required by the Company.

d. Supports shall not be welded to the equipment unless otherwise specified.

e. Temporary lugs and supports attached to the piping by welding shall be removed by
cutting them off and grinding the remaining fin flush with the pipe.

10.4.6 Shoes or Pad Supports

a. Shoe support thickness and height must be checked and followed as per drawing
prior to Fit Up and welding.

b. Shoe pads for low alloy steel piping shall be same of the same materials as the pipes.

c. Saddle type supports with pad shall be provided for piping size 30-inch NPS and
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larger (ref. SAES-L-310 para 16.2.4)

d. For shoes shall be welded to piping with careful way avoiding any welding defects

10.4.7 Dummy Supports

a. Installing additional dummy leg supports other than those in the design drawings shall
not be installed without prior to review and approval.

b. 6mm 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.

c. All dummy supports which are pre welded in shop shall have its base plate tack
welded with an additional length of stanchion pipe than it is mentioned in the drawing

d. Proper marking shall be done on Pipes prior to field installation of dummy support on
field to avoid any distortion in stanchion pipes

10.4.8 Low Friction Supports

a. If Teflon sheets or similar low friction materials are used to function as low friction
supports are to be installed, the following shall apply;

1) Sliding surfaces shall be protected during all construction activities including painting
and sandblasting.

2) Provision shall be made to allow angular adjustment of the bearing surface during
installation, so that an even distribution of the load can be assured.

3) 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).

4) For sliding supports, bearing surfaces shall be sufficiently clean to secure

unrestricted movement.

10.4.9 Spring Supports

a. Installation of constant and variable spring hangers shall be in accordance with the
manufactures instruction, design drawing and procedure.

b. The spring setting shall be verified that they are machining the design requirements

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

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d. All springs shall be in compression, so that failure will not result in the complete
release of load.

e. Springs 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. There
stops shall be banded or locked in place so they cannot be easily dislodged during
erection or hydro-test. The travel stops shall be tagged indicating “Remove after
Hydro-test”.

f. Each spring hanger assembly must be capable of sustaining the load during hydro-
testing, which is equal to 2 times the operating load.

10.4.10 Hanger rods

a. 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.

1) Rods hangers shall not be used for lines 12” NPS and larger in liquid service or
multi-phase flow.

2) All hangers shall be provided with means for vertical adjustment.

3) Suitable locking devises shall be used at all threaded connections of the hanger
assembly (double nuts).

4) Rod hangers shall be subjected to tensile loading only.

5) Practicality for replacing them with rigid pipe supports should be evaluated and
implemented, during construction.

10.4.11 Cold Spring.

a. Cold springing shall be permitted only when specified and shown on the drawings.

b. If cold spring is specified, an examination shall be made of supports and restraints for
conditions that can either prevent desired movement or cause undesired movement.

c. If the cold spring gap or overlap is not as specified, the piping shall be approved by
Company.

10.4.12 Inspection and Testing

a. At the completion of the installation, piping systems shall be dry, clean, and free from
dirt, slag and other loose foreign materials.

b. Company shall perform an erection walk-down to verify that the work is in accordance
with the Piping and instrumentation Diagrams (P & IDs) and drawings.
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c. Leak tests shall be performed in accordance with approved Pressure test procedure
and SAES-A-004-General requirements for pressure testing/ SAES-L-150-Pressure
testing of plan piping and pipelines.

d. Inspection and testing shall confirm to Saudi ARAMCO Typical Inspection Plan
(SATIP).

11. NON-DESTRUCTIVE TESTING

11.1 Before non-destructive Testing, all welded joint shall be visually inspected by
Contractor’s QC.

11.2 Non-destructive testing shall be in accordance with approved NDT Procedure and the
following applicable Saudi ARAMCO Test and Inspection Plans (SATIPS).

11.2.1 SATIP-NDE- LPT-01 Liquid Penetrate Testing

11.2.2 SATIP-NDE- MPT-01 Magnetic Particle Testing
11.2.3 SATIP-NDE- RT-01 Radiographic Testing
11.2.4 SATIP-NDE- UT-01 Ultrasonic Testing

11.3 Weld Repairs

11.3.1 All NDT report shall be submitted to the Contractor to verify the defective welds
(if required)
11.3.2 Defects shall be removed by grinding.
11.3.3 Excavated repair areas shall be 100% examined visually prior to welding repair to verify
complete removal of defects.
11.3.4 Repair weld joints shall be examined in accordance with the original weld requirements.

12. PAINTING

12.1 Painting on installed / Pre-fabricated piping shall be in accordance with SAES-H-001-Coating

Selection & Application Requirement for Industrial Plant & Equipment/ SAES-H-002-Interal
and External Coatings for Steel Pipelines and Piping

13. TEST PACKAGE

13.1 Hydrostatic Pressure Test Package shall be in accordance with SAES-A-004 / SAES-L-350 /
SAIC-A-2003 General Requirement for pressure testing. And a sample test package will be
submitted separately

14. REINSTATEMENT

14.1 Reinstatement shall be performed method statement and final piping punch listing and

piping
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reinstatement shall be conformed to SAIC-L-2022.

15. CONTRACTOR’S DOCUMENT AND REPORT

15.1 Contractor shall prepare and keep up-to-date documents giving detailed technical information
of Fabrication & Installation. These documents shall include but not be limited the following
information.

15.1.1 Welding procedure qualifications (WPS)

15.1.2 Welding procedure qualification test results(PQR)
15.1.3 Welder’s qualification test results
15.1.4 Weld log book, giving each part or fabricated component

15.1.5 Inspection and Check list (SATIPs and SAICs)

15.1.6 Other documents by Company requirement

16. ATTACHMENT I. APPLICABLE SAUDI ARAMCO CHECK LIST & TEST REPORT (only)
FOR PIPING WORK

16.1 Saudi ARAMCO Inspection Checklist for Leak-test

16.1.1 SAIC-A-2001 Review Procedure-Pressure Testing (All Applications)

16.1.2 SAIC-A-2003 Review of Test Package Preparation
16.1.3 SAIC-A-2004 Verify Pneumatic Test Medium (Air, Nitrogen & Inter Gas) & Bubble
Solution (for Leak Testing)
16.1.4 SAIC-A-2005 Review of Leak Test Procedure (Bubble Test)
16.1.5 SAIC-A-2007 Review Procedure-Lay-up of Piping Systems or Vessels
16.1.6 SAIC-A-2008 Verify Test Medium for Hydrostatic Testing & Lay-up
16.1.7 SAIC-A-2009 Verify Test Equipment (Safety Assessment)
16.1.8 SAIC-A-2010 Pre-Test Punch Listing of On-Plot Piping
16.1.9 SAIC-A-2013 Inspection of Filling & Pressurization (Hydro-test)
16.1.10 SAIC-A-2015 Visual Inspection at Test Pressure
16.1.11 SAIC-A-2016 Visual Inspection of Air Test on Re-pads & Weld-Plus-Ends
Couplings
16.1.12 SAIC-A-2017 Depressurization & Disposal of Hydro-test Water
16.1.13 SAIC-A-2020 Pressurization of Pneumatic Test (Strength & Service)
16.1.14 SAIC-A-2021 Inspection of Pneumatic Test (Strength & Service)
16.1.15 SAIC-A-2022 Depressurization of Pneumatic Test (Perform Leak Test)
16.1.16 SAIC-A-2023 Pressurization for Bubble Leak Test (Using Air, Inert Gas)
16.1.17 SAIC-A-2024 Inspection of Leaks for Tightness Testing

16.2 Saudi ARAMCO Inspection Checklist for Fabrication & Installation

16.2.1 SAIC-L-2011 Piping Pre-Installation Inspection (Prior to On-Plot Work) Including

SPEC Check
16.2.2 SAIC-L-2012 Pipe Laying Spool Erection & Assembly on Pipe-racks and
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Sleeper ways
16.2.3 SAIC-L-2013 Inspection of Piping Branch Connections
16.2.4 SAIC-L-2014 Inspection of Bolted Flange Joint Assembly
16.2.5 SAIC-L-2015 Inspect Threaded Joint Engagement (Gap Control)
16.2.6 SAIC-L-2016 Inspection of Venturi, Restriction Orifice and Flow Orifice
16.2.7 SAIC-L-2017 Piping / Equipment Internal Cleaning Inspection
16.2.8 SAIC-L-2018 Inspection of Pipe Support and Pipe Anchor Installation
16.2.9 SAIC-L-2019 Installation of Buried Piping (U/G On-Plot Metallic Piping)
16.2.10 SAIC-L-2020 Inspection of Thermo well (TW) Installation
16.2.11 SAIC-L-2021 Inspection of Chemical Injection Quill/Nozzle, Corrosion
Monitoring Station & Sample Connection (Including Receipt)
16.2.12 SAIC-L-2035 Cutting & Assembly Fit-up
16.2.13 SAIC-L-2036 Inspection of Cold Bend Process
16.2.14 SAIC-L-2037 Inspection of Cold Bending Process

16.2.15 SAIC-L-2038 Final Inspection for Release of Fabricated Piping

16.2.16 SAIC-M-2011 Final Inspection (Re-Instatement) of Structural Steel Installations

16.3 Saudi ARAMCO Inspection Checklist for Welding

16.3.1 SAIC-W-2005 Pre-Welding Inspection (Shop & Field) of Plant Piping

16.3.2 SAIC-W-2006 In Process Welding Inspection
16.3.3 SAIC-W-2007 Post-Welding Visual Inspection (Plant Piping)
16.3.4 SAIC-W-2008 Review Procedure – Weld ID & Traceability, Process Control
Tracking (SAEP-1160 Database)
16.3.5 SAIC-W-2010 Receiving Inspection of Welding Consumables
16.3.6 SAIC-W-2032 Control of Welding Consumables – Plant Piping (Site Strange,
Handing, Conditioning & Issuance)
16.3.7 SAIC-W-2035 Welder & Welding Operator Certification (Plant Piping)
16.3.8 SAIC-W-2036 Inspect/Verify Piping & Weld Modifications* After Initial Welding
Acceptance (Rework & Weld Repairs)
16.3.9 SAIC-W-2037 Procedure & Inspection of Socket & Seal Welded Threaded Joints
(Gap Control, See also SAIC-L-2015)

16.4 Saudi ARAMCO Test Report for Leak-test

16.4.1 SATR-A-2001 Pressure Test Report (2005 Edition of SAES-A-004, 2642-Eng)

16.4.2 SATR-A-2002 Calibration Test Report – Pressure Gauge
16.4.3 SATR-A-2003 Calibration Test Report – Temperature Gauge
16.4.4 SATR-A-2004 Calibration Test Report – Pressure Recorder
16.4.5 SATR-A-2005 Calibration Test Report – Temperature Recorder
16.4.6 SATR-A-2006 Calibration Test Report – Pressure Test Relief Valve
16.4.7 SATR-A-2007 Pre-Pressure Test Checklist (Form)
16.4.8 SATR-A-2008 Internal Cleanliness Report (Piping Systems & Equip)
16.4.9 SATR-A-2010 Leak Test Report
16.4.10 SATR-A-2011 Re-Instatement Checklist (Form)
16.4.11 SATR-A-2012 Positive Material Identification (PMI) Report
16.4.12 SATR-A-2013 Positive Material Identification (PMI) Log Sheet

16.5 Saudi ARAMCO Test Report for Welding

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16.5.1 SATR-W-2003 Welder Performance Qualification Test Record

16.5.2 SATR-W-2004 Post Weld Heat Treatment Table/Schedule
16.5.3 SATR-W-2005 PWHT Report Form
16.5.4 SATR-W-2006 Daily Weld Fit-up Insp. Report (For SAEP-1160 Database)
16.5.5 SATR-W-2007 Daily Weld Production Report (Replace by SAEP-1160 Database as
Requested)
16.5.6 SATR-W-2008 Weld Summary, Welder Performance and Non-Destructive (NDT)
Tracking System (See SAIC-W-2008-Follow The 500 Weld Rule)
16.5.7 SATR-W-2009 Welding Rod Oven Calibration/Verification Report
16.5.8 SATR-W-2010 Welding Consumables Issuance Record
16.5.9 SATR-W-2011 Welding Machines Verification Report
16.5.10 SATR-W-2012 Hardness Test Report (With SAEP-1160 Weld Tracking Criteria)
16.5.11 SATR-W-2013 Weekly Welder Repair Rate Report

16.5.12 SATR-W-2017 Weld Overlay Inspection & Summary Report / Record

16.5.13 SATR-W-2018 Weekly Welder Repair Assessment and Tracer Welds Report
16.5.14 SATR-W-2019 Weekly and Cumulative Weld Status Report