Professional Documents
Culture Documents
TABLE OF CONTENTS
1.0 SCOPE
2.0 PURPOSE
3.0 REFERENCES
4.0 DEFINITION
5.0 RESPONSIBILITIES
6.0 PROCEDURE
7.0 DOCUMENTATION
1.0 SCOPE:
1.2 To ensure that all required inspection and tests have been performed during
construction and the work complies with all project specification and drawing
requirements.
2.0 PURPOSE:
2.1 This procedure applies for all Surface Preparation and Painting works to be
carried out by NSH and its sub-contractors.
3.0 REFERENCES:
4.0 DEFINITIONS
SAOMPP - Saudi Aramco Onshore Maintain potential Program.
NSH - Nasser S. Al-Hajri Corporation
Subcontractor - Authorized enterprise to carryout construction
activities on behalf of Contractor)
Supplier (or Vendor) - Any person, firm, partnership, company corporation or
combination thereof with which the BUYER has sent
the QUOTATION REQUEST or placed the
PURCHASEORDER.
Supply - All material, equipment and services to be provided
whether. Expressly or by implication under the
PURCHASE ORDER.
FBE - Fusion Bond Epoxy.
APCS - Aramco Paint and Coating Specification.
5.0 RESPONSIBILITIES:
engineering & Standards etc. and to control for the specified Piping activities
including test and inspection etc. for this particular job. He will coordinate will all
discipline heads for this related activity & report to General Manager.
The Piping Manager is responsible for the total piping fabrication works as per
the project related approved documents at site/shop and plan for the weekly
work schedule and controlling for all the piping works comply with the project
requirement including safety & Quality . He will report to Site Construction
Manager.
The Piping Superintendent coordinates with personnel at Shop & Site to Plan for
the fabrication of daily, weekly piping works as per baseline schedule, and
allocates the job to the concerned supervisors, and control the piping works
including daily monitoring etc. in all the areas accordance with safety, Quality
and Productivity respectively. He will report to Piping Manager.
5.6 QC Engineer
The QC Engineer will be responsible for the necessary inspections and tests at
shop and specified place and to be carried out for all the activities involved in
the above ground piping fabrication works as per the specified Inspection & Test
Plan (ITP). He will report to QA/QC Manager.
Piping Inspector is responsible to inspect all the piping materials related the
specified areas he will do the dimension check, Grade, etc. as per IFC prior to
fabrication. He will inspect the beveled ends and giving clearance for fit-up etc.
He is also responsible for Calibration of all testing instruments/machineries and
using necessary precision tools etc. to meet accordance with the Quality on
specified piping works He will report to QA/QC Manager.
The Welding Inspector inspects the joint after fit-up and gives clearance for
welding. Once welding is completed, visual inspection will be done and non-
destructive inspection shall be carried out as required by the specification. The
welding report shall be prepared by QC Inspector and submitted to SAOMPP.
He will report to QA/QC Manager.
The Site Supervisor will be directly involved in the planning and execution of the
activities involved in the fabrication works. He will be responsible for the
preparation of fabrication plan, Safety Action Plan, Safe Work Plan and work
permits if required prior to commence of any activities. He should raise Request
for Inspection (RFI's) to the QC dept. at appropriate stages of the work as
detailed in the ITP. He will report to piping Manager.
5.10 Foreman
The Piping Foreman will be responsible for the direct execution of works
involved in the fabrication process according to the plan and will directly control
and issue instructions to the working personnel. He will provide written
instructions to welders by issuing "Welding Instruction Sheets" that cover the
fundamental requirements of the Welding Procedure Specification (WPS). He
will also ensure that works are performed with proper tools/equipment and good
housekeeping around the working area. He will report to Piping Manager.
Safety Manager / Supervisor will make sure that all the safety requirements are
fulfilled prior to start of the job. Job Safety Analysis/Safety Task Assignments
will be strictly implemented by daily basis in order to avoid any loss of time.
prior to Make PR etc. Preparation of weekly, monthly and overall schedule will
be done and the same will be monitored on daily basis accordance with the
baseline schedule and will monitor the daily/weekly/monthly delay concern etc.
he will report to Site Construction Manager & Project Manager.
5.13 Materials Department
The materials Dept. is responsible for shifting all materials from store yard to
fabrication yard as per material requisition made by fabrication supervisor. Also
the fabrication completed spools shifted to erection site. All the documents and
records in connection with materials shall be maintained for traceability. Records
will be made as per isometrics for material shifting and an updated status of
materials stock and transfer to site will be done on daily basis. Material
department will report to Material Manager.
6.0 PROCEDURE
All fabricated A/G Piping work shall be prepared, primed and painted in accordance with
SAES-H-001.
All below grade surfaces except the bottom one, on all concrete foundation, buried
concrete thrust anchors and pipe supports shall be coated in accordance with APCS-10
to an elevation of 300 mm above finish grade.
All kilometer marker posts shall be painted yellow in accordance with SAES-H-101V &
APCS-22.
All welded structure shall be grit blasted using abrasive grit to obtain minimum
cleanliness and surface profile requirements as per the paint data sheet. Abrasive used
shall be dry and free of contaminants.
External FBE coat, sections of Pipeline 8 meter beyond the point of exit from the ground
if the exit angle is 45 degree or less and for camel/road crossings and 1 meter beyond
the point of exit from ground if the exit angle is 46 degree or more.
Anchor bolts shall be painted with APCS-1C or shall be galvanized. The paint shall be
applied up to the bottom of the thread.
Abrasive blasting shall be carried out only when the steel is at least 3 deg. C above dew
Point.
6.1.7 The APCS-113C can also be used over an existing coating that is
sound and has good adhesion on the steel substrate. This procedure is
normally applicable on isolated steel valves, spools and fittings that are
not protected with either cathodic protection or galvanic anode.
6.1.8 Ditch preparation and sand padding requirements for onshore buried
pipe are given in SAES-L-350 and SAES-L-450.
6.1.9 At road crossings, the minimum allowable surface preparation prior to
coating shall be near white metal Sa 2.5 except for APCS-113C.
6.1.10 Cast iron pipe that has been shop-coated with enamel (or similar) does
not require additional external coating prior to burial. Bare cast iron pipe
shall be externally coated prior to burial.
6.1.11 Buried stainless steel lines shall be externally coated with halide-free
liquid coating or visco-elastic coating APCS-113C depending on
operating temperature.
6.1.12 Pipes to be thrust bored shall be coated with APCS-104A or APCS-
104B first layer and APCS-113A top layer. For open cut excavation,
APCS-113C can be used over APCS-104A or APCS-104B.
6.1.13 When external coating is required, the selection table given in
paragraph 5.4 & 5.6 of SAES-H-002 shall be used.
6.1.14 Coating systems listed in paragraphs 5.4 through 5.6 of SAES-H-002
shall not be used under conditions that violate service limitations or
other requirements given in the applicable APCS data sheets. Only
approved products shall be used.
6.1.15 Preheating pipe prior to FBE coating application on the internal girth
welds shall be done by heat induction coils only.
6.1.16 Wellhead components shall be coated in accordance to SAES-H-001
and SAES-H-004.
gas, condensate and crude oil. When internal coating is required, the
selection table given in paragraph 5.3 of SAES-H-002 shall be used.
6.2.2 Internal coatings used in potable water service must meet Food and
Drugs Administration (FDA), National Sanitation Foundation (NSF) or
equivalent requirements for suitability for use in contact with drinking
water. The certificate shall be renewed every 24 months.
6.2.3 Application of phenolic primer prior to the application of FBE shall not
be controlled manually. A machine shall be used to ensure that the
travel of application is constant and that the DFT will not exceed one mil
(25 microns) in all areas. One mil is exceeded if the “peaks” of steel
substrate are no longer visible.
6.2.4 For onshore application, the robotic crawler machine (consisting of
blasting and coating equipment, dry film thickness gauge and holiday
detector) shall be used for internal field girth welds of pipe strings with
diameters ranging from 8 to 36". If isotope is used as the girth weld
locator, it should be backed up with a video camera for real time
inspection to ensure that blast cleaning and coating application are
done in the girth weld area. For pipe diameters larger than 36", the
coating application can be done manually by qualified contractors with
the approval of CSD/Coatings Team.
6.2.5 In the offshore, a semi-robotic system shall be used in the application of
specialty liquid coating on internal girth welds by qualified and
experienced contractors. This is applicable for sub-sea pipelines with
diameters ranging from 8" and above.
6.2.6 For sour gas and Wasia water services, field application of FBE shall
not be used for internal protection of girth welds for both onshore and
offshore pipelines.
6.2.7 All Blasting and Coating Personnel shall be certified by SAUDI
ARAMCO in accordance with the requirements of SAEP-316
The work will be coordinated with the coating Inspector who will initiate each step
of the painting process.
The coating contractor supervisor shall fill out a log, on a daily basis,
recording all problem areas, delays, non-compliances, and corrective
actions taken for SAUDI ARMCO inspector witnessing and
surveillance.
Prior to blasting, rough welds and cut-off shall be ground to small radius and
weld spatter shall be removed by grinding or chipping.
Compressed air supply shall be free of oil, moisture and contamination. This shall
be checked by QC Inspector by holding blotter paper attached to clip board
approximately 45-60 cm. In front of blast nozzle during air flow only with nozzle
pressure of 50 PSIG for approximately 1minute.
After blasting abrasive, materials shall be removed from cleaned external surface
by dry brushing or blowing down with clean dry compressed air.
Abrasive cleaned surface shall be primed before the surface condition degrades
below the specified cleanliness level.
Paint and thinner shall be stored in well-ventilated area earmarked for SAUDI
ARAMCO project material.
Paint shall not be used from container which shows sign of leakage.
Paint which have gelled shall not be used and any paint skin must be cut and
removed before application.
All paints shall be thoroughly mixed before application. For quantities above 5
liters power stirrer shall be used. If sludge has formed a bottom of container
mixing shall be continued until the paint is homogenous.
If the thinner is required, the type and quantity to be added shall be given in
SAUDI ARAMCO Data Sheet.
Welds edges shall be given a brush applied stripe coat prior to normal painting.
Recoating shall not be carried out until the earlier coat has completely cured.
The finishing coating shall be generally free of runs, Sags, drips, dry spray or
foreign matter.
Upon completion of the paint application, the dry film thickens shall be checked.
All the areas where the dry film thickness are below the above minimum values
need to be build-up.
For small areas than 0.1sq.m the paint film will be removed by means of grinding
machine using at least 80 grit disc sanders to expose the bare metal surface.
Spot blasting can also use as an alternated method.
For areas greater than 0.1sq.m the paint film shall will be blasted off to bare
metal surface.
In both cases the edge of the coating around the bare metal will be feathered up
to 50 mm.
The bare metal areas will be brushed to remove dust debris then paint will be
reapplied. For area larger than 0.1sq.m paint will be sprayed.
The paint after curing shall be checked for dry film thickness.
7.0
Item No Item Description Painting System Color Manufacture
All tool box talk attendance sheets must be turned over for submission to
HSE department.
Housekeeping:
All tools shall be inspected color coded prior to use; replace damage tools
from store.
Electrical tools/equipment must be properly checked color coded before
using (project standard is 110 volts supply / 220 volts tools shall require
SAOMPP approval).
Operate the tools according to the operations manual.
Mobile equipment shall comply all safety requirements and inspected by
respective operators and drivers prior to operation.
Flagmen shall be deployed to assist the moving equipment.
All other non-mobile equipment shall be complied with all the safety
requirements prior to deployment.
Permit To Work:
All permits to work required must be valid and approved before the start
of the job.
Permit original copies must be in the site; inside the permit box.
All conditions provided in the permit must be complied and maintained
form the start up to completion of the works.
For night work, workers list shall be attached on all permits.
When an unsafe condition or conditions occur, the task will be stopped for
immediate rectification of the condition.
There may be light lifting activity; contractor’s lifting and permit procedure
shall be strictly followed.
All equipment must have valid certification and color inspection sticker.
Operator to implement daily inspection with checklist prior to use.
Operator must possess the valid SAG heavy driving license, 3rd party
certification and medical examination fit to work.
Certified rigger to be available during the operation.
All lifting gears, sling and tackles must have valid certification and color
coding and inspected prior to use.
Flagman shall be available; equipped with red and green flags and
whistles.
Electricity:
Lighting facility (tower lights & flashing lights) for night work are provided.
All energized equipment shall be properly grounded.
Qualified mechanic/electrician shall be deployed during the operation to
respond the need for lighting relocation, etc. and also to act as fire
watchers.
Panel boards or extension cords used in site shall be proper checked and
color coded.
To mitigate tripping hazard, power/electrical cables shall be either
installed in between scaffold planks or elevated in access/egress
portions.
Lightings and generators locations shall be marked in the drawing
attached.
Road/ traffic safety:
All vehicles and equipment in the site shall observe strict road safety; that
is follow site speed limit 30kph and 15kph in congested areas, seat belt
fastened by driver and all passengers, pedestrians are respected and
allowed to pass first all the time.
Passing other vehicles not allowed.
All headlights on at all times.
Signboards for speed limit are provided (30kph site speed).
Crossing signs are provided in entrance and exit gates.