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SAUDI ARAMCO STANDARD FOR PIPING QC

QA-QUALITY ASSURANCE- Is the planning and organizing of system program to maintain a required
level of quantity or reliability. This includes auditing the systems in operation and related controls to
assure that they are being executed properly and functioning as expected.
QC - QUALITY CONTROL- Is a part of quality assurance

implements the letters by


examining the physical characteristics and comparing them to established and
acceptable quality and documents as stated in quality assurance program or plan.
ITP - Inspection Test Plan mean the document sequences for quality activities in process,highlights
the applicable quality and inspection criticality.
S -Surveillance: QA/QC organization to monitor work in progress without notice of construction
organization.
W-Witness point: QA/QC organization shall be notified with the timing inspection in advance,
however the inspection or test shall be performed as schedule if the QA/QC representative is not
present.
H- Hold point: QA/QC organization shall be notified of the timing of inspection on test in advance,
inspectiontest shall not be carried out ,without the QA/QC organization representative in advance.
NCR- in case of violation of quality document by the contractor NCR will be issued. The fulfillment or
the required corrective action will be mandatory by the contractor.
R- Review:
* Documents review = Review
* Material receiving = Witness/Surveillance
* Installation and Testing =Hold Point
UNDER GROUND PIPING/PLUMBING
SAES-S-010 -Sanitary Sewers
SAES S 020 -Industrial Drainage and Sewers
SAES S 030-Storm Water Drainage System
SAES S 040-Water system
SAES S 050 - Sprinklers and Standpipe Systems in Buildings
SAES S 060 Plumbing Code
SAES S 070 Utility PipingSystem
SAES A 004 -General Requirements for Pressure Testing
SAES B 017 -Fire Water System Design
SAES A 104- Wastewater Treatments for Pressure Testing
SAES L 610 -Non Metallic Piping
SAES L 460 - Pipe Line Crossing Under Road
SAES L 350 - Construction of Plant Piping
SAES L 1024 -Installation Piping Handing & Storage
SAES A 114 -Excavation and Backfill

SAES A 104- Wastewater Treatments for Pressure Testing


SAES L 1034 -RTR (fiber Glass) Pressure Pipe and Fittings
SAES L 1029 - RTR (fiber glass) Sewer Pipe and Fittings for Gravity Flow
SAES S 002 - Support Plastic Piping
SAES L 0012 - Non Sleeve Road Crossing for Pipelines
SAES L 0036 -Sleeve Crossing for Restrained Pipelines
SAES X400 -CathodicProtection of Buried Pipelines
SAES X 500 - CathodicProtection of Vessel and Tank internals
SAES X 600 -Cathodic Protection of Plant Facilities
SAES S 1004 - Concrete thrust blocks, details of utility pipe
SAIC S 4054- RTR & Thermoplastic Pipe Installer Qualification
SAIC S 4055- RTR and Thermoplastic Piping Receiving (Pressure and Sewer pipe)
SAIC S 4056 RTR and Thermoplastic Piping Handling, Storage and Preservation
SAIC S 4057- Assembly of Plastic (PVC,UPVC, CPVC and HDPE Piping
SAIC S 4058- Assembly and Laying of RTR piping

GRP- Is the resistant corrosive effect of mixture with low concentration of acids,
nearly neutral salts, solvents and acoustic substances, under both internal and
external pressure.
GRE-Glassfiber Reinforced Epoxy
GRP-Glassfiber Reinforced Plastic
RTRP-Reinforced Thermosetting Resin Pipe ASTM D4024 reinforced without

aggregate
RMRP Reinforced Mortar Resin Pipe= a fiber glass w/ aggregate
HDPE- High Density Poly Ethylene Pipe
PVC-Poly Vinyl Chloride ASTM D1785
CPVC-ChlorinatedPoly Vinyl Chloride
DWV - Drain Waste and Vent
Typesof RTR/GREJoint.

1.Adhesive Bondedjoint and( EPOXY FIELD LAMINATION FOR BUILD UP)


2.Flange joint
3. Rubber Seal joint
4. Butt / Lamination joint
5. Mechanical Coupler

A) UNRESTRAINED JOINTS
1. Gasketed Bell and Spigot
2. Gasketed Bell and Bell Coupling for use for spigot End pipe
B)
1.
2.
3.

RESTRAINED JOINTS
Bell spigot ,Adhesive Bonded
Butt and wrap w/ Reinforced Overlays
Mechanical Joint Flange and Restrained GasketedJts.
THESE TYPES OF ADHESIVE BONDED

1. Tapered Bell and Spigot


2. Straight Bell and Spigot
3. Tapered bell and Straight Spigot
7.9 Adhesive and Solvent Cleaner Shall be store at 38 C not less than 9 months from shipment.
LEGEND
PL- Plain End
CS- Cylindrical Spigot
TB- Tapered Bell
FF- Flat Face

E- Epoxy
T- TensilS- Strength
RTR PIPE Material :
COOLING WATER - OFFERED PRESSURE 11 barg
OILY WATER SEWER- 2 barg
FIRE WATER 17.5barg
RTR(FUTURE PIPE INDUSTRIES )FPI
(BUTT & WRAPLAMINATION JT.)(EPOXY FIELD LAMINATION for BUILD UP)
DIA
THICK BOND AREABUILD UPTHICK BOLT TORQUE (Nm/ ftlb)
25 mm 2.5 mm
50+50
30+301.9mm15/11
50mm
2.4 mm
50+50
30+302.4 mm20/14.7
80 mm 2.8 mm 50+5035+353.6 mm35/25.8
100 mm2.8 mm 50+50
35+353.6 mm45/33.1
150 mm 2.8 mm
50+50
40+40
4.1 mm40/29.5
200 mm 3.5 mm 60+60
60+60
4.4 mm80/59.0
250 mm 4.3 mm 75+75
60+60
4.8 mm85/62.6
300 mm
5.1 mm 90+90
70+70
5.6 mm130/95.8
350 mm 5.9 mm 105+105
80+80
6.6 mm180/132.7
400 mm 6.7 mm 120+120
90+90
7.4 mm185/136.4
450mm
7.5 mm
135+135
100+100
8.3 mm180/132.7
500 mm 8.3 mm
150+150
115+115
9.2 mm 175/129
600 mm
9.9 mm 180+180
135+135
11 mm255/165
700 mm 12.5mm
245+245
220/162.2
800mm
320/236
900 mm
335/247
1000mm
365/269.2
1050 mm 18 mm 290+290
378/278.7

Under Ground Bolt required ceramic Fluoropolymer coatedA307 GR. B, A563 GR.A with 2 washer
. 300 mm distance from sewer to Potable Water
U/G Steel pipe material ASTM A53, API 5L grade B

SAES S 010 Sanitary Sewers


SAES S 020 Industrial Drainage and Sewers
- Air Gap minimum of 25 mm for the lip of drain Funnel not exceed 100mm
- Pipe material RTR, Fittings RTR Wye Lateral
- Pipe 150 to 450mm
- Maximum surface travel of any liquid to catch basin shall not greater than 15 meters
- 5.5.3slope not less than 1:65 (1.5%)
- 5.7.3 The lip of drain funnel shall be elevated 80mm above the ground
- 5.9.5 Invert of the outlet shall be at least 25mm lower than the invert of the lowest
incoming sewer in the manhole
- 5.10.1clean out as per standard drwg. Shall be provided 100mm(4 inch)
- Vents 100 mm pipe diameter, shall be sloped to drain back to the manhole with low
point. And required water tight in 4 hrs those back filled shall be tested in 24 hrs
SAES S 030 - Storm Water Drainage System
SAES S 040- Water System
- UL/FM Approved (all valves)
- UL- Underwriter Laboratories
- FM- Factory Mutual
- NFPA- National fire Protection Association
- NSF National Sanitation Foundation

MATREIAL
12LC0U Steel pipe ASTM A53, API5L Grade B
12FE0U RTR Fiber Glass
AWWA C950 FIBERGLASS PRESSURE PIPING

AWWA American Water Works Association C151 Cement Line with Coated
Non metallic pipe fittings CPVC, HDPE,RTRP
5.7.11 Flange Flat face/Full Face Gasket
SAES S 050Sprinkles and Stand Pipe System Buildings
SAES S 060 - PLUMBING CODE
SEE Bracing Standards
COPPER NICKEL
UPS Utility Piping System
UPC Uniform Plumbing Code
AWWA C950 Fiber Glass Pressure pipe
Copper Tube for Piping required Type L
TYPE of Copper Joints
1.Composite Flange
2.Butt Welding
3. Socket Welding
4.Copper
Nickel
Capillary

Bracing

Fitting

or

Connectors

IAPMO International Association of Plumbing Official


UPL Uniform Plumbing Code
SOLVENT CEMENT shall be conform to the FF.
ASTM D2564- PVC to PVC
ASTM F493 - CPVC to CPVC or PVC
Plastic Pressure Pipe installed under any building floor, slab or cellar unless piping is fully encasedin
concrete or protection of steel pipe
SAES S 070 - Installation of Utility Piping

UTILITY PIPING INCLUDES

a)
b)
c)
d)
e)

Potable Water (Raw and Drinking Water)


Raw/Fire Combined Water
Dedicated Water system
Sanitary Works
Industrial drains and Sewers
PIPEmaterialif stored in rack or bearings board support at least 75 mm wide spaced or 3 meter and
1.5 m from the end of pipe.
10.7.3 Fire Water Lines and Piping with internal Pressure in excess of 200 PSI shall be required
Woven Geotextile
12.1 Joints shall be restrained type (adhesive Bonded) Butt and Wrap Lamination Joints)
Mechanical type joints or unrestrained typegasketed bell and Spigot Type Joints,
AWWAC950 sec.7.7These joint shall be assemble in accordance with the manufacture procedure,
Heating blanket shall be used to cure Adhesive bonded Joints.
12.3 Flat washer shall be use under nuts and bolt heads on non metallic flanges
17.2 Piping larger than 250 mm nominal pipe size shall be assemble in trench.
19.6 Requirements of pressure gauges, pressure recorder, calibration interval, calibration certificate
shall be accordance with SAES A 004.
Field repair for RTR Piping shall be made in accordance with the pipe manufacture pre qualified
repair
procedure.

FIBER GLASS DEFFECTS PIPE& FITTINGS


AIR BUBBLE (VOID) Not to penetrate any surface limits apply to all surfaces, maximum
Dimension 1-2 mmdiameter, 0.5mm thickness.
FOREIGN INCLUSION-Not penetrate any surface limits apply to all surfaces, maximum depth 1mm
PIT (pinhole) Maximum depth 0.25 mm, maximum width 1.0 mm
POROSITY (pinhole)
SCRATCH Maximum depth 0.40 mm not to exceed liner thickness
WORMHOLE (surface void)
WRINKLE

Thermo plastic and RTR fittings shall be stored in their original containers. Fittings shall be stored in
a building or under cover that allows free air circulation.

Solvent cement and primer for thermoplastic piping shall be stored in an air conditioned building
with a maximum temperature of 25 C.

Adhesive for RTR piping shall be stored in an enclosure where temperatures do not exceed 38 C.
Gasket, O-rings and locking keys shall be stored flat on the racks below 38 C and out of direct sunlight
Training certificate (or proof of training) for installing RTR piping system must be obtained from RTR
piping manufacturer. This certificate is valid for one year or the duration of the project, which ever is
the first.
Hardness Test (BARCOL)--- 33 % above ACCEPTANCE CRITERIA at least 5 READINGS.
Mixed the Resin according to the recipe. The mixed ratio is 1 kg of resin is to 10 ml of hardener.
RTR Bonding Wrapping Joints Material
Resin mixed with IPD or
Resin mixed with Easy Fit
WovenRoving orNon Woven Polyester Fiber (for wrapping butt joints)
Cabosil Powder ( for tacking and filling)

Adhesive Cement or Easy fit Adhesive (for adhesive joint or for tacking butt jt.)
Non Woven Polyester Fiber
Glass veil surface mat (Top Tape)
CLEANING using a clean cloth soaked in acetone.
CURING for maximum chemical resistance, the product should be cured at 125 C

for 1 hr.
16-5- Geotextile shall be used defending upon the soil condition to prevent soil wash away around the
pipe

ADVISED HEATING UP/CURING TIME (HOUR) ADHESIVE JOINT FOR MEDIUM TEMPERATURE
<=95 C
PRESSURE TESTING:
The test shall be hydro tested at least 1.5 times the minimum design pressure of the piping system but
not less than 150 psig for minimum two (2) hrs.
Pressure gauge shall have range the test pressure with in the 30% to 80% of the full range (one month
expirationfor calibration.
Test Manifold shall be tested at least 1.2 times system of test pressure.
Sanitary and other gravity sewers (including oily water ) in which the internal pressure from static
head and or friction does not exceed 103 kpa (15 psi)
Relief valve of adequate capacity set at 5% above at the test pressure or a maximum of 170 kpa(25
psig) (onemonth expiration for calibration) (16.5bar x5 shift %=+)=17.3
The test pressure shall be maintained for a minimum of 2 , maximum of 4 hrs.while the joints are
inspected for leakage.
If for justifiable safety reasons the line must be backfilled, then the joints shall remain exposed during
testing, otherwise the shall be a 24 hour recorded test.
Records/ Reports Related to Quality
CAR-Corrective action report NCR- Non Conformance Report
STQ-Technical Query RequestPAF- Preventive Action Form
FCR- Field Change ReportQCR- Quality Control Report
QCR-Quality Control Report RFI- Request for Inspection
ITP-Inspection Test PlanSSSS-Supplier Subcontractor Submittal Sheet
MRI-Material Receiving Inspection QPQ- Quality Personal Qualification
MSS-Material Submission SheetWMS-Work Method Statement
ON PLOT PIPING
ASME B31-1- Power Piping

Steam Power Generation


Co Generation Plant
Steam Generation Plant

ASME B31.3 Process Piping

Refineries
Petro chemical
Pump station within the plot limit of refinery or petrochemical plant
Designated pipe ways or corridors with in process piping facility
Steam generating facility with in the process piping
Tank farm with in facility designated in process piping
Terminals for transporting and shipping crude oil and its derivatives
Shop fabrication skid mounted piping such as metering skid and corrosion inhibitor injection
skid

ASME B31.4 Pipe line transportation system for liquid Hydrocarbon and other liquid
ASME B1.20.1-Pipe Threads General purpose
ASME B16.5 - Pipe Flange and Flange fittings
ASME B31.8- Gas Transmission and distribution Piping System
ASME 1X- Boiler and Pressure Vessel
NACE National Association of Corrosion Engineers
ASME American Society of Mechanical Engineers
ASTM- American Society of Testing Materials
ASNT- American Society of Nondestructive Testing
API- American Petroleum Institute
MSS Manufactures Standard razation Society of Valve
AWWA- American Water works Association
AWS American Welding Society

SAUDI ARAMCO STANDARD


SAES A 004 General Requirement for Pressure Testing
SAES A 007 Hydrostatic Testing fluid and Layup Procedure
SAES L 109 Selection of Pipe Flanges Stud bolt and Gasket
SAES L 110 Limitation on Pipe Joints and Components
SAES L 120Piping Flexibility Analysis
SAES L 150Pressure Testing of Plant Piping and Pipe Lines
SAES L 310 Design of Plant Piping
SAES L 351 Bolted Flange Assembly
SAES L 460 Pipeline Crossing Under roads and Railroads
SAES L 420Scraper Trap Station Appurtenances
SAES L 100Applicable Codes and Standard for Pressure
SAES L 133Corrosion Protection Requirement

SAES L 315Steam Tracing and Jacketed Pipe


SAES L 440 Anchors for Buried Pipe lines
SAES L105Piping Class and Material Spec
SAES L 125 Safety Instruction Sheet for Piping and Pipe Lines
SAES L 350 Construction of Plant Piping
SAES L 450 Construction on land Near Shore Pipe line
SAES L 108 Selection of Valve
SAES L 130 Material for Low Temperature Service
SAES L 140 Thermal Expansion Relief in Piping
SAES L 351 Bolted flange Assembly
SAES- L 109 Selection of Pipe Flange, Stud Bolts and Gasket
SAES L 131 Fracture Control of Carbon Steel Line Pipe
SAES L 410 Design of Pipe Lines
SAES L 610Non Metallic Piping
SAES A 206 PMI for Alloy and Stainless Material
Utility Identification
1. Fire Water
2. Service water
3. Cooling Water
4. Demi water
5. HP Steam
6. LP Steam
7. MP Steam
8. HP Condensate
9. MP Condensate
10. LP Condensate
11. BFW
12. Plant Air
13. Instrument air
14 Fire Water
15 Service water
16 Cooling Water
17 Demi water
18 HP Steam
19 LP Steam
20 MP Steam
21 HP Condensate
22 MP Condensate
23 LP Condensate
24 BFW
25 Plant Air
26 Instrument air
27 LP Nitrogen
28 LP Flare

Utility System:
S TEAM
W ATER
A IR
N ITROGEN
INSPECTION ACTIVITES:
1. Iso Drawing Is an easy method of drawing image, all vertical line are drawn verticality
but all horizontal line are drawn in 30 deg to the base line.
2. P&ID Is an schematic illustration of piping instrumentation and system equipment
components.
3. Test Package Contents:
1 Review of test package preparation
2 Pressure test Diagram
3 Test legend and symbols
4 Drawing Index (P&ID and Iso Drawing)
5 Verification of testing Equipment &Preparation
6 Pre Test Punch list
7 P& ID
8 Isometric Drawing with weld map
9 Line history reports ( joint log sheet)
10 Compaction test Report (U/G)
11 Survey report
12 Internal cleaning /air blowing Report
13 Test calibration Certificates (test manifold, gauges, recorder, PZV)
14 Water analysis report
15 Pressure Test and visual inspection report
16 Depressurization & disposal of Hydro Test
17 Flange face , Gasket verification ,Bolt tightening report
18 Re-instatement Inspection
19 Safety Instruction Sheet
20 NDT Report (PT, MT,RT,PWHT, PMI,Hardness test)

4.Bolt Tightening and Tensioning Inspection(RFI)


Check the FF:
Flange serration and Gasket Verification (class and type)
Damage Criteria for Flange Raised Face:
See SAIC -L -2002
Flange Alignment, Tilt 1.6mm,2.4 bolt hole acceptable tolerance
Bolt and nuts material, color code and stencil,
Tightening Sequence
Check the torque value
Torque wrench certificate

Bolt tightening group approved w/ ID

TORQUE MULTIFLIER 700 FOOT POUNDS


(Torque Ratio=1 : 185 )
EX: 1 3/8 -B7m Coated ft/lb
30%=320 devidedto 18.5=17.29ft/lb to be set in small torque wrench
100%= 1067 devidedto 18.5= 57.7 ft/lb to be set in small torque wrench
B7 Process and General Services
L7/L7M- Low Temp Services
B16 Upper Intermediate Temp sevices
B7M/L7M- Wet Sour Services
Ceramic Fluor polymers Coated Bolts- Under Ground Piping
Torque value SEE: SAIC-L-2001
NOTE:
ASME B31.3 sec 335.2.3 Bolt Length- Bolts should extend completely
through their nuts.
Any which fail to do so are considered acceptably engaged if the lack of
complete engagement is not more than one thread.

5.Fit/Up Inspection(RFI)
Check the FF:
3mm clearance for Butt, 1.5 for socket Joint Clearance,
Material class, sched ,and code no. as per drawing
Color coding,
Heat no.
Square, Level, Plumb and Dimension
Orientation as per Drawing
Internal Pipe Cleaning
Pipe- Identified by NB and Thickness is defined by Schedule based on
ANSI B31.3
Tube- Identified by OD
Eccentric Reducer (Suction) To avoid cavitations to maintain Elev. (BOP)
in rack
Concentric Reducer ( Discharge) Vertical pipe line
Vent hole For venting of hot gas which may get generated to welding
(Test pressure 175kpa= 17 barg)
6.Valve Installation Inspection(RFI)
Check the FF:
Material Class as per Drawing
Flange Face serration inspection
Flange face Coating

Color Coding
Valve Handle Orientation
Flow Direction (if required)
NOTE: SAES L 108
4.7.1 Field Testing Butt wel and socket end valves in nominal
pipe size (NPS) 2
inches and smaller are excemp inches and smaller are exempt
from the above
field testing requirements.
Test Holding Time 1 minute., 900 class and high pressure shall
be test in min 5 min.
And no visible leakage.
NPS 2 and smaller all ratings- 10%
NPS 14 NPS and less than ASME 600 -25%
NPS 14 and above 100 %
2 and ANSI class 600 100 %
2 and API rating 2000 psi above 100%
7.Weldolet Installation and Branch Connection (RFI)
Material Class as per drawing
STUB IN or OUT
Clearance, Dimension
8. Pump Flange Alignment .20 mm Tilt(RFI)
9. PZV to Pipe Flange Connection Alignment
10. Orifice Flange Inspection (RFI)
Check The FF:

Flange face serration inspection

Check the material class, size and code as per drawing


Tilt acceptable tolerance
2.4 mm for bolt hole or free
Orifice Flange Internal smooth Grinding
Jack bolt and orifice tap orientation

11.Material Inspection (RFI)


Check the FF:
Manufacture and Vendor approved by company
Material approved by company
Mill test Cert. with signed by 3rd party

1.6 mm Tilt(RFI)

Color Coding ,
NDE Report with signed by 3rd party
Test Report with signed by 3rd party
Heat no.
Visual Inspection

12. Spool Released Inspection (FAB Shop)(RFI)


Check the FF;
As per ISO Drawing
NDT Report acceptable
13. Pre installation Inspection ,Air Blowing , Pipe end Capping(RFI)
14.Valve testing Inspection as per Project Required Percentage.(RFI)

15. Hydro testing Inspection(RFI)


Check The FF:
Test Package signed prior for test, All cert. shall be attached in
test package a
(punch A should be closed)
Hydro Test Manifold with Tag and Certificate.
Hydro test Manifold x1.2 test pressurewith certificate
Relief Valve plus 5% of test Pressurecheck the certificate
validity of 1 week
Pressure gauge Range 30%-80% (1 barg=14.5 psi)check the
certificate 1 month validity
2 or 3 Pressure Gauge shall be installed
Safety Permit
Line Design pressure X 1.5 = Test pressure
Check the Barricade Tools and Equipment
30 min Holding Time
Check the temporary blind thickness is suitable as the
test pressure
Vent should be installed in highest point and shall be open
during filling of water.
E8018 defines:
E Electode
80 Tensile Stregnth (psi x 1000)
1 Positional Capabilities
8 Flux coating & Electrical Characteristic
WELDING

SMAW- Shielded Metal Arc Welding (DCRP- Direct Current Reverse Polarity)
GTAW- Gas Tungsten Arc welding ( DCSP Direct Current Straight Polarity)
GMAW- Gas Metal Arc Welding
SAW- Submerge Arc Welding
FCAW-Flux Cored Arc Welding
NDT- Non Destructive Test
PWHT- Post Weld Heat Treatment
PT-Penetrate Test (Cleaner, Penetrate, Developer)
RT- Radiography Test
MT Magnetic Test
PMI-Positive Material Identification
UT- Ultrasonic Test
Hardness TestLUBEREF ARAMCO
CS, LTCS, SS, DSS- Butt Weld fittings ASME B16.9
CS, LTCS, SS, DSS- Socket Welding Threaded Fittings ASME B 16.11
150,300,600 Raised Face , 150 may also flat faced
900,1500,2500 Gasket groove type
SPIRAL WOUND Gasket ASME B16.20
SAES L 109
NON METALLIC Gasket ASME B16.21
RING JOINT Gasket ASME B16.20
GATE VALVE - 04 SAMMS-001
GLOBE VALVE 04 -SAMMS-002
CHECK VALVE -1/2- 1 - BS-EN-ISO-17292
BALL VALVE- 2 ~ - 04 -SAMMS-051
PLUG VALVE (lubricate) -04 -SAMMS -053
BUTTERFLY VALVE High Performance 04 SAMMS-047
General Requirements for Valves - 04 SAMMS- 035
Valves Inspection and Testing -04 SAMMS-048
CG - A53 Hot dip galvanized.
FE - GRE U/G pipe
PD - HDPE
PU - CPVC
CC- Carbon
CC 05-07 Nace
CJ - Alloy
SD Stainless steel
SX- Duplex (NACE)

Prepared by M.Ajmal Khan