QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • General pressure test requirements • Test RVs to be set at 5% above test pressure and tested within 1 week/1month for new projects/maintenance work, respectively. • Pressure gages calibration interval not to exceed 1 month • SIS purpose is to provide adequate information. • SIS required for each plant equipment/piping • Hydrotest Fluids/Lay-up Procedures • POSITIVE MATERIAL IDENTIFICATION • SPACING of atm./low pressure tanks • Diking requirements • Definition of FIRE-HAZARDOUS ZONE & EQUIPMENT • FIRE PROOFING Requirements for Plants • Long exposed bolts 75mm or greater for piping/equipment containing flammable/combustible liquids in fire-hazardous zone shall be protected with flame impingement shields per Std. Dwg. AC-036404. • Safety requirements for plant/operations support buildings • Control buildings, PIBs, SIHs, UPS rooms, and communications buildings/rooms shall have a fire detection and alarm system. • Design of Fire water system • Fire water tank STORAGE CAPACITY • Valves on the immediate suction/discharge of the pumps shall be car-sealed open. • Check valves shall be provided on the discharge of all fire water pumps upstream of the discharge block valves. • The minimum permissible size of distribution piping is 200 mm (8 in) in process areas and 150 mm (6 in) in other areas. • All below grade block valves in plant areas shall either have their stems protruding abovegrade or be equipped with position indicators abovegrade. • Provision of Fire Water Pumps • A pressure relief valve shall be provided on the discharge of each enginedriven pump. • Machine Safety Guarding • Plant facilities to have acceptable access/egress for personnel and equipment • A stairway landing shall be provided for every 5m of vertical rise wherever practical. • Safety guards (commonly known as "drop bars" or "safety gates") shall be provided on fixed ladders serving elevations 1.2 m or more above the ground, existing platform or floor… • A cage, well, or ladder safety system shall be provided where a single length of climb is greater than 6 m but does not exceed 15.2 m. • PLANT LAYOUT REQUIREMENTS • Windsocks shall be installed at plant facilities handling flammable gases, volatile liquids or toxic materials. • Residential housing not to be located closer than 500m of a hydrocarbon processing plant area perimeter fence. • Restrictions on the Use of Plastic/RTR Tanks and Vessels • Emergency shutdown/isolation and depressurizing • ESD systems shall be provided for facilities that process, transport, or otherwise handle combustible, flammable, or potentially toxic materials.. • EIVs required for pumps/compressors, etc. categorized as fire-hazardous equipment… • EIV valve pressure classes that are listed in Table 1 shall be provided with power operators. Jerry Hernandez
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SAES-A-004, See also 00-SAIP-06 SAES-A-004, para.5.5.1 SAES-A-004, para. 7.1.5 SAES-A-005, para. 4.1 SAES-A-005, para. 4.2 SAES-A-007 SAES-A-206, See also 00-SAIP-07 SAES-B-005 SAES-B-005, para. 5.3 SAES-B-006, para. 4.0 SAES-B-006, para. 5.0 SAES-B-006, para. 6.4
SAES-B-014 SAES-B-014, para. 7.1 SAES-B-017 SAES-B-017, para. 6.2 SAES-B-017, para. 12.7/12.8 SAES-B-017, para. 12.8d SAES-B-017, para. 12.9b SAES-B-017, para. 12.11a SAES-B-017, para. 13.1 SAES-B-017, para. 14.4.5 SAES-B-053 SAES-B-054, para.4.1 SAES-B-054, para.7.6.9 SAES-B-054, para.8.4.1.7
SAES-B-054, para.8.4.1.3 SAES-B-055 SAES-B-055, para. 6.10 SAES-B-055, para. 8.6 SAES-B-055, para. 8.7 SAES-B-058 SAES-B-058, para. 5.1 SAES-B-058, para. 6.2 SAES-B-058, para. 8.1
11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • EIVs, including those having fireproofed actuators, and actuating buttons shall be clearly labeled. • Protective shields required for piping/equipment • ONSHORE WELLSITE SAFETY REQUIREMENTS • Spacing from OIL and GAS wells • A well is in a populated area if the population density index within the 30 ppm H2S rupture exposure radius exceeds 20… • Spacing from Well flare burn pits • All wells shall have a manual lower master valve. • Safety Valves required on Oil Wells and Low Pressure Gas Wells… • Hydrocarbon injection well flowlines shall each be provided with a check valve in the wellhead piping. • All wellheads shall be protected with a guard barrier per Saudi Aramco Standard Drawing AB-036685. • Wellsites in populated areas shall be enclosed by a fence meeting the specifications of SAES-M-006 (Type III). • Wind sock to be permanently installed at each hydrocarbon production or injection wellsite in populated areas. • Requirements for Abandoned wells • ONSHORE PIPELINE SAFETY REQUIREMENTS • Rupture Exposure Radius (RER) • PIPELINE LOCATION CLASSIFICATION (Class 1, 2, 3, 4) • No pipeline greater than 24” is permitted within 1 km of hospital or school • Pipelines in Class 3 and Class 4 locations shall be inspected more frequently than pipelines in Class 1 and Class 2 locations… • PIPELINE CORRIDORS/SPACING/Clearance from Power Lines • All pipelines shall be placed in designated corridors which are a minimum of 60m wide. • Induced voltages in pipelines and communications cables shall not exceed twelve (12) volts under normal (i.e., steady-state) conditions. • Minimum spacing between pipeline and parallel overhead powerline to be.. • EMERGENCY ISOLATION VALVES REQUIRED FOR PIPELINES • Emergency isolation valves shall be installed between pipeline sections of different location classes defined in ASME B31.8. • SAFETY IDENTIFICATION AND COLOR CODING • Exposed fire water piping shall be painted red. • Bellows type PZVs to have safety green bonnets indicating vented bonnets • • • • • • • • • • • •
PZVs BLOCK VALVES to be PAINTED ORANGE Break-away spools shall be painted safety orange with black stripes. Above ground potable water lines in plant areas to be painted blue (not applicable to piping in RO PLANTS) PIPING SHALL BE LABELED. TANKS/EQUIPMENT SHALL BE LABELED. ELECTRICAL AREA CLASSIFICATION EMERGENCY EYEWASHES & SHOWERS Bulk Plants Fire/Safety Requirements Bonding, grounding, and other types of protection against ignitions arising out of static or stray electrical currents at shall meet SAES-P-111. Design criteria for pressure vessels A joint efficiency of 85% or higher shall be specified for the design of all pressure containing components of ASME SEC VIII D1 pressure vessels. Corrosion allowance shall be based on achieving a minimum service life of twenty years.
Jerry Hernandez
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SAES-B-058, para. 9.1 SAES-B-061 SAES-B-062 SAES-B-062, para. 6.1 (Table 2) SAES-B-062, para. 6.3 SAES-B-062, para. 6.6.4 (Table 3) SAES-B-062, para. 8.1.3 SAES-B-062, para. 8.3 SAES-B-062, para. 8.4 SAES-B-062, para. 8.7.1 SAES-B-062, para. 8.7.2 SAES-B-062, para. 8.8 SAES-B-062, para. 9.0 SAES-B-064 SAES-B-064, para. 5.0 SAES-B-064, para. 7.0 SAES-B-064, para. 7.1 SAES-B-064, para. 7.2 SAES-B-064, para. 10.0 SAES-B-064, para. 10.3 SAES-B-064, para. 10.9 SAES-B-064, para. 10.10 (Table 3) SAES-B-064, para. 11.0 SAES-B-064, para. 11.1.1 SAES-B-067 SAES-B-067, para. 4.2.1a SAES-B-067, para. 4.2.2d, SAES-J600, para. 5.2 SAES-B-067, para. 4.2.4a SAES-B-067, para. 4.2.4c SAES-B-067, para. 4.2.5 SAES-B-067, para. 4.3 SAES-B-067, para. 4.4 SAES-B-068 SAES-B-069 SAES-B-070 SAES-B-070, para. 8.2 SAES-D-001 SAES-D-001, para. 6.6 SAES-D-001, para. 6.7.1 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • The type of heads for vessels shall be specified as ASME 2:1-ellipsoidal or ASME hemispherical. • Nozzles and manways shall be flanged. Nozzles less than 2” NPS may only be used in utility services. • Threaded or socket-welded connections are prohibited in hydrogen, lethal, wet sour and caustic services. • Unless provided on overhead piping, all vessels shall be provided with vent and pressure relief connections. • Vessels that contain catalyst or packing shall be provided with 24 inch minimum inside diameter manways… • Horizontal vessel shall be supported by one fixed and one sliding saddles… • Provide davit for lifting of equipment on vessels containing removable internals such as trays, packing and relief valves. • For carbon and low alloy steels, the following process services require PWHT: caustic soda, MEA, DGA, etc…… • Repairs, alterations and rerating of pressured equipment • Local hydrotesting can be performed for nozzle repairs and alterations. • Design criteria for ATM. And LOW PRESSURE TANKS • External (open-top)/internal floating roof tanks in accordance with API STD 650 shall be specified for the following services….. • Fixed roof tanks shall be used for all services for which floating roof tanks are not required. • No corrosion allowance is required for atmospheric pressure tanks storing crude oil or petroleum products… • For tanks storing water, a corrosion allowance shall be specified… • Emergency venting capacity per API STD 2000 and explosion hatch per NFPA 68 shall be provided for API STD 650 fixed roof tanks. • Vertical, cylindrical, flat bottom tanks built to API STD 620 and API STD 650 shall have 1 in 120 upward-sloped bottoms. • Tanks Nozzles and Manways requirements • Block valves shall be installed directly at the tank nozzles. • Bellows expansion joints shall not be used in tank piping. • Cast iron valves shall not be used. • A minimum of one level gauging instrument per tank, readable from grade, shall be specified. • Provisions for manual gauging shall be specified for all atmospheric tanks, in addition to the automatic gauging devices. • A spiral stairway shall be specified for external floating roof tanks & fixed roof tanks over 6 m in height. • Stairs shall be located on the upwind side with respect to the prevailing wind direction of the tank. • Regulated Vendors List for Pressure Vessels/Tanks • STORAGE TANKS INTEGRITY • DESIGN OF SMALL TANKS • Tank selection criteria • A minimum of one level gauging instrument per tank, readable either from grade or from an access platform, shall be specified. • Stairways, Ladders and Platforms - REQUIREMENTS • Design Criteria for Shell and Tube Exchangers • Design Criteria for AIR COOLED Heat Exchangers • Design Criteria for Electric Heat Exchangers • Regulated Vendors List for Heat Transfer Equipment • Design Criteria for Fired Heaters • Design Criteria for FLARES Jerry Hernandez
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SAES-D-001, para. 6.8.2 SAES-D-001, para. 7.1.7 SAES-D-001, para. 7.1.8 SAES-D-001, para. 7.1.10 SAES-D-001, para. 7.3.4 SAES-D-001, para. 9.3.1 SAES-D-001, para. 10.3.1 SAES-D-001, para. 11.3.1 SAES-D-008 SAES-D-008, para. 10.7 SAES-D-100 SAES-D-100, para. 6.1/6.2 SAES-D-100, para. 6.4 SAES-D-100, para. 7.2.1 SAES-D-100, para. 7.2.2 SAES-D-100, para. 8.7.3.1 SAES-D-100, para. 8.8 SAES-D-100, para. 9.2 SAES-D-100, para. 9.3.1 SAES-D-100, para. 9.3.5 SAES-D-100, para. 9.3.6 SAES-D-100, para. 9.8.2 SAES-D-100, para. 9.8.4 SAES-D-100, para. 9.13.2/3 SAES-D-100, para. 9.13.5 SAES-D-101 SAES-D-108 SAES-D-109 SAES-D-109, para. 6.0 SAES-D-109, para. 9.5.2 SAES-D-109, para. 9.7 SAES-E-004 SAES-E-007 SAES-E-015 SAES-E-101 SAES-F-001 SAES-F-007 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • CENTRIFUGAL PUMPS • Centrifugal Pump Type Selection criteria • Centrifugal Pumps shall run counterclockwise when viewed from the driver. • Bearings shall be oil lubricated unless exempt from the scope of 31-SAMSS-004 or ASME B73.1 and ASME B73.2. • Pump drivers required…. • Suction piping to all pumps, with the exception of vertically suspended double casing pumps and horizontal self priming pumps, shall have a straight length of pipe of at least 5 times the suction nozzle diameter immediately upstream of the nozzle. • Reducers in suction piping shall be of the eccentric type with the flat uppermost… • POSITIVE DISPLACEMENT PUMPS • Submersible Pumps and Motors • Regulated Vendors List for Rotating Equipment • Lubrication, Shaft Sealing and Control Oil Systems • Cleanliness Standard for LUBE OIL/SEAL OIL • SELECTION REQUIREMENTS FOR INDUSTRIAL COATINGS • INTERNAL/EXTERNAL COATINGS FOR STEEL PIPELINES/PIPING • • • • • • • • • • • • • • • • • • • •
External coating at transitions shall extend above ground either 1m or 8m Hand-applied tape wraps shall be of the "pressure sensitive" type, meaning they can be applied over dry primer or no primer without adverse effect on adhesion. Buried stainless steel lines shall be externally coated with APCS-105, APCS-113A, APCS-113B… Pipe to be thrust bored shall be coated with APCS-104 or APCS-105. For new construction, buried carbon steel piping in diameters 3 inches and smaller that are not externally coated with APCS-104 or APCS-105 shall be coated with a suitable heat shrink tubing approved by the RSA. Internal coatings used in potable water service must meet FDA or equivalent requirements for suitability for use in contact with drinking water. COATING REQUIREMENTS FOR CONCRETE SURFACES PAINTING REQUIREMENTS FOR INDUSTRIAL FACILITIES The use of reclaimed slag abrasives is prohibited except…. The use of sand as a blasting abrasive shall be permitted only as follows… Sand shall not be used as a blasting abrasive for immersion coatings. Abrasive blasting shall be carried out only when the steel surface is at least 3°C above the Dew Point. The compressed air supply shall be free of oil, moisture and contamination. An operational deadman remote control valve to be attached to the nozzle. All personnel entering tanks or vessels after abrasive blasting shall wear rubber-soled shoes with clean disposable covers, sweatbands and lint-free gloves. Paints and thinners shall be stored in well-ventilated buildings. Paints which have exceeded the shelf life given in the Saudi Aramco Data Sheet (see definition in SAES-H-101) shall be set aside and not used. Prior to application, all paint shall be thoroughly mixed until it is homogeneous. For quantities over 5L, a power stirrer shall be used. Partial mixing and use of two-component and multi-component coatings is prohibited. Paint shall not be applied if one or more of the following conditions exist unless the paint is specifically formulated for the condition…
Jerry Hernandez
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SAES-G-005 SAES-G-005, para. 4.1.7 SAES-G-005, para. 4.4 SAES-G-005, para. 4.7.1 SAES-G-005, para. 4.10 SAES-G-005, para. 5.2.3
SAES-G-005, para. 5.2.4 SAES-G-006 SAES-G-007 SAES-G-101 SAES-G-115 SAES-G-116 SAES-H-001 SAES-H-002 (002V FOR DATA SHEETS) SAES-H-002, para. 5.1.4 SAES-H-002, para. 5.1.7
SAES-H-002, para. 5.1.11 SAES-H-002, para. 5.1.12 SAES-H-002, para. 5.1.14
SAES-H-002, para. 5.2.2
SAES-H-003 SAES-H-100 SAES-H-100, para. 5.2.2 SAES-H-100, para. 5.2.3 SAES-H-100, para. 5.2.3.4 SAES-H-100, para. 5.3.2 SAES-H-100, para. 5.4.1 SAES-H-100, para. 5.4.2 SAES-H-100, para. 5.4.4
SAES-H-100, para. 6.1 SAES-H-100, para. 6.4 SAES-H-100, para. 7.3 SAES-H-100, para. 7.6 SAES-H-100, para. 8.1.1 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Primer, intermediate coat, and topcoats shall be of contrasting colors. • Paints for immersion service (including vapor zones) shall be applied by spray, preferably airless. • Holding primers, if used, shall be approved by CSD. • When painting the interior of tanks or vessels, forced ventilation shall operate continuously throughout the paint application and curing period. • All tank and vessel coatings shall be holiday checked using a wet sponge at 67.5 volts. • Paint thickness within 2m of anode connections shall be at least 30% greater than the specified minimum dry film thickness. • Repair Procedure for Immersion Coatings • APPROVED PROTECTIVE COATING SYSTEMS/DATA SHEETS • SAFETY REQUIREMENTS FOR PAINTING • Storage, Handling and installation of externally coated pipe • Coated pipe not to be rolled or dragged on the ground • Damaged FBE/PE Coating REPAIR • Spec. for over-the-ditch external FBE coating of field welds • Hand Applied Tape wrapping of buried pipe • The width and overlap of the tape shall meet the requirements of Table 1. • On above ground portions of lines, the tape shall have a minimum of 50 mm overlap (25 mm for 50-mm wide tape) to allow for end shrinkage. • APCS-109 tape shall be double wrapped. • Each new roll of tape shall overlap the end of the preceding roll by a minimum of 150 mm. • The tape wrap applicators and the Crew Supervisor shall be certified in accordance with SAEP-316 in the "Pipeline coating" category. • Tapewrap In Conjunction With Other Coatings – special cases • Tape shall be protected from oil spray during sand stabilization. • When tapewrap is used in any road crossings, the system shall include a layer of outerwrap. • Outerwrap APPLICATION CRITERIA • TAPEWRAP REPAIRS • Spec. for applying heat shrink sleeves to coated pipes • Heat-shrink (HS) sleeves shall not be used in contact with liquid hydrocarbons, including oil-contaminated ground water. • Minimum acceptable width of the HS sleeves shall be… • Surface Preparation prior to HS sleeve application… • Preheating shall be by propane torches or induction heaters. • Contact pyrometers shall be used for all temperature measurements. • Approved Vendor Installation Procedure for Heat Shrink Sleeves • Technically Acceptable Instruments • Instrumentation Basic Design Criteria • Sour gas supply shall not be used in lieu of instrument air. • Instrumentation Symbols/Identification • All instruments shall be identified with a tag (mark) number. • Instrumentation Drawings & FORMS • Process Flow Metering • Thermowells shall be located a maximum of 20 nominal pipe diameters downstream of the meter. • All parallel pipe lines with adjacent orifice flanges or orifice fittings shall have a minimum spacing of 300 mm (12 in) between flange outside diameters if horizontal taps are required. • Orifice flanges in adjacent lines shall be staggered so that no two pairs of orifice flanges are less than 1 m (3 ft) apart. Jerry Hernandez
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SAES-H-100, para. 8.1.2 SAES-H-100, para. 8.2.1 SAES-H-100, para. 8.2.3 SAES-H-100, para. 8.2.4 SAES-H-100, para. 8.2.6 SAES-H-100, para. 8.2.7 SAES-H-100, para. 8.3 SAES-H-101/101V SAES-H-102 SAES-H-200 SAES-H-200, para. 5.1.2 SAES-H-200, para. 6.3 SAES-H-201 SAES-H-203 SAES-H-203, para. 8.1.1 SAES-H-203, para. 8.1.1.1 SAES-H-203, para. 8.1.1.2 SAES-H-203, para. 8.1.2 SAES-H-203, para. 8.1.6 SAES-H-203, para. 8.2.1 SAES-H-203, para. 8.2.2 SAES-H-203, para. 8.2.3.1 SAES-H-203, para. 9.0 SAES-H-203, para. 11.0 SAES-H-204 SAES-H-204, para. 5.1 SAES-H-204, para. 5.3 SAES-H-204, para. 6.2 SAES-H-204, para. 6.3.1 SAES-H-204, para. 6.3.2 SAES-H-204V SAES-J-002 SAES-J-003 SAES-J-003, para. 6.0 SAES-J-004 SAES-J-004, para. 4.1.4 SAES-J-005 SAES-J-100 SAES-J-100, para. 5.0 (PIP 4.2.4) SAES-J-100, para. 5.0 (PIP 4.2.7.2)
SAES-J-100, para. 5.0 (PIP 4.2.7.3) 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Interconnecting piping shall be limited to a maximum length of 6 m (20 ft) for meters in control loops. • Installation/design of Pressure Instruments • Pressure gauges shall have safety glass. • Standard ranges shall be selected such that the normal operating pressure falls between 30% and 70% of the scale range. • Process connections shall be ½ inch NPT. Connections for pneumatic tubing shall be ¼ inch NPT female, minimum. Electrical conduit connections shall be ½ inch or ¾ inch NPT. • Electric switch contacts shall be snap acting, single-pole, double-throw (SPDT) as a minimum. • All connections from the process line up to and including first block valve shall be bridge-welded per Standard Drawing AB-036521. • All pressure instrument installations shall be equipped with vent/drain valves. • Level Measurement Requirements • Local instruments shall be accessible at grade level or from a platform. • Connections to vessels or standpipes shall be made with Type II, heavy welding bosses, as shown on Saudi Aramco Standard Drawing AE-036175. • No fittings shall be allowed between this primary block valve and the connecting boss, except for a single pipe nipple. • Threaded connections between the root valve and the boss shall be seal or bridge welded per Saudi Aramco Standard Drawing AB-036521. • Standpipes CRITERIA • Gauge glasses in hydrocarbon service shall be transparent or reflex type heat-resistant glass with chambers machined from solid bar alloy steel and with drop-forged alloy steel covers. • Gauge glasses shall not be used on refrigerated storage tanks. • Use of other GAUGE TYPES… • Application of magnetic type gauge • Application/installation of Automatic Tank Gauging systems • For water storage tanks, float-and-cable type instruments with counter weight and gauge board are acceptable. • All transmitters used for level service shall be smart and microprocessor based. • Installation/design of Temperature Instruments • All temperature sensing elements shall be installed in thermowells. • Thermowells shall not be located between suction screens and inlets of pumps, compressors, or turbines. • Thermowells shall be 316 stainless steel unless alternative metallurgy is specified or dictated by process conditions. • Insertion length in process piping shall be per Standard Drawing AB036019. For process vessels and columns, the maximum insertion length shall be 600 mm (24 inches). • Thermocouple Design and Installation • Resistance temperature detectors (RTDs) shall be used when greater accuracy is required than is possible through the use of thermocouples. • RTD Design and Installation • Bimetallic dial thermometers shall be used wherever local temperature indication is required & shall be installed in thermowells. • Bimetallic temperature switches shall not be used. • Minimum PZV inlet size shall be ¾" threaded or 1" flanged. • Inlet flanges for PZVs smaller than 16” to be class 300 minimum except… • PZV type selection criteria • PZV MATERIALS Jerry Hernandez
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SAES-J-100, para. 5.0 (PIP 4.2.8.2) SAES-J-200 SAES-J-200, para. 5.1.3 SAES-J-200, para. 5.1.8 SAES-J-200, para. 5.2.7
SAES-J-200, para. 5.2.8 SAES-J-200, para. 6.1 SAES-J-200, para. 6.4 SAES-J-300 SAES-J-300, para. 4.1 SAES-J-300, para. 4.3 SAES-J-300, para. 4.4
SAES-J-300, para. 4.5 SAES-J-300, para. 5.1.1
SAES-J-300, para. 5.3.1 SAES-J-300, para. 5.4/5.5/5.6 SAES-J-300, para. 6.0 SAES-J-300, para. 8.0 SAES-J-300, para. 8.4 SAES-J-300, para. 10.5 SAES-J-400 SAES-J-400, para. 5.1.1 SAES-J-400, para. 5.1.2 SAES-J-400, para. 5.2.4 SAES-J-400, para. 5.2.6
SAES-J-400, para. 6.2 SAES-J-400, para. 7.1.1 SAES-J-400, para. 7.2 SAES-J-400, para. 9.1.1/9.1.3 SAES-J-400, para. 9.2 SAES-J-600, para. 4.1.2 SAES-J-600, para. 4.1.3 SAES-J-600, para. 5.0 SAES-J-600, para. 6.0 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • PZV SIZING • PZV Application Requirements • PZV setting(s) shall always be at least 10% or 100 kPa (15 psi), whichever is greater, above the maximum operating pressure. • Thermal relief valves shall be provided to protect sections of blocked-in liquid piping against over pressure due to thermal expansion of the liquid. • PZVs in combustible gas service shall discharge at a minimum distance of 30 m from any source of ignition. • Discharge of PZVs in all liquid service (except water), toxic and corrosive vapors shall be to a closed system. • When gate valves are used as block valves in relieving paths they shall be installed with the stem horizontal or sloping down away from the valve. • All PZVs block valves to be car-sealed. • Relief Valve Inlet/Outlet Piping – design considerations • Upstream and downstream vent valves required between PZV and block valves • A Relief Valve Authorization (Form 3099A-ENG) shall be completed for each PZV. • Testing and Inspection of relief valves, for initial installation and maintenance, shall comply with the requirements of SAEP-319. • Control Valves DESIGN/INSTALLATION • Control valves shall not be used as emergency shutdown (ESD) valves (ZVs), nor as emergency isolation valves (EIVs). • Control valve sizes 24" and smaller shall be integrally flanged which shall comply with ASME B16.5. • Flangeless control valves shall not be used in hydrogen services, etc… • Threaded control valves shall not be used. • Control valve body materials shall be… • A threaded drain plug shall be provided for non-self-draining type control valve bodies (i.e., bodies which can trap liquid) applied in liquid sour services and liquid toxic services. • Control valve sizing shall generally be based on ISA 75.01, "Flow Equations for Sizing Control Valves”. • The minimum control valve nominal body size shall be 1”. Nominal body sizes 1¼ inch, 2½ inch, 3½ inch, 5 inch or higher odd numbers shall not be used. • Acoustic or thermal insulation shall not be used for control valves in continuous or intermittent services. • The control valve manufacturer shall be made responsible for correctly sizing the actuators based on the technical specification(s) and the data specified on the ISS. • Each control valve connected to a Distributed Control System (DCS), shall be operated through its own field wiring, on a standard 4 - 20 mA signal or standard digital communication signal in compliance with SAES-J-003. • Positioners, Electro-Pneumatic (I/P) Transducers and Boosters for control valves • A handwheel shall be provided on valves when local manual control is required by the Proponent. • Each control valve shall be provided with a valve position indicator. • The direction of flow shall be cast or steel-stamped on the valve body, or alternatively a stainless steel arrow shall be permanently fixed… • Name plates shall be provided for all control valves. • Control valves shall be installed in horizontal lines. During flushing and hydrotesting the control valves shall be removed from the piping system.
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SAES-J-600, para. 7.0 SAES-J-600, para. 8.0 SAES-J-600, para. 8.1 SAES-J-600, para. 8.9 SAES-J-600, para. 9.1 SAES-J-600, para. 9.2 SAES-J-600, para. 9.4.3 SAES-J-600, para. 9.4.4/9.4.5 SAES-J-600, para. 9.7 SAES-J-600, para. 9.7.6d SAES-J-600, para.10.0 SAES-J-600, para.11.0 SAES-J-700 SAES-J-700, para. 4.0 SAES-J-700, para. 4.1.2a SAES-J-700, para. 4.1.2b/c SAES-J-700, para. 4.1.5 SAES-J-700, para. 4.1.10
SAES-J-700, para. 6.1 SAES-J-700, para. 6.2.1
SAES-J-700, para. 6.7.1 SAES-J-700, para. 7.1
SAES-J-700, para. 7.6
SAES-J-700, para. 8.1 SAES-J-700, para. 8.2 SAES-J-700, para. 8.7.1 SAES-J-700, para. 8.8.1 SAES-J-700, para. 8.8.2 SAES-J-700, para. 9.1
11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Block and bypass valves shall be provided as standard for each control valve installation except… • The type of bypass valve shall be similar to that of the control valve and manually operable. • PROVISION of Protective Shields and Flame Impingement Shields • CONTROL BUILDINGS Design/Construction • Double doors shall be installed to provide outside access to the control room, equipment rooms and rack rooms as required. • All incoming cables must be sealed in accordance with Section 15.4 of SAES-P-104 and SAES-O-126. • Cabinets shall not be mounted on blast resistant walls. • Battery rooms shall be ventilated in accordance with SAES-K-002 and SAES-P-103. • Plumbing installations and fittings shall be in accordance with SAES-S-060. • Critical instrument and control systems shall be connected to a UPS system. • Instrument Air Supply Systems • All equipment of the air system shall be capable of being isolated by block valves. • Instrument Air Compressors selection criteria • Provision of instrument air receiver to damp out system fluctuations and to provide surge capacity in the event of duty compressor shutdown • Provide regenerative desiccant air dryer and not refrigeration dryers • All safety relief valves for instrument air service shall be equipped with a lifting device. • Instrument Air Distribution System – General Requirements • Pressure testing of supply system and distribution system per SAES-L-150, using dry instrument air or inert gas is required (hydrotest not permitted). • Electrical Systems for Instrumentation • Supply voltages for all process instruments • Cables used for instrumentation signals shall be selected per Table 2. • All wiring shall be tagged at each end with each wire tag having two labels. • Required safety ground and instrumentation circuit ground must conform to NEC, Article 250. • INTRINSICALLY SAFE SYSTEMS • FOUNDATION FIELDBUS SYSTEMS • CENTRIFUGAL COMPRESSORS • Centrifugal compressors in process air or gas service shall comply with 31SAMSS-001. • Compressor skids shall be grade mounted, and compressor nozzles shall be upward facing. • Shaft seals shall be of the dry gas seal type unless specific process conditions dictate otherwise… • RECIPROCATING COMPRESSORS • Plant or Instrument air compressors furnished to 31-SAMSS-002 shall be provided with sunshades for protection against the additional heat load due to solar radiation. • Direct seawater cooling of the compressor is not acceptable. • Air compressors shall be located in non-classified areas whenever possible. • Steam Turbines • Combustion Gas Turbines • DIESEL ENGINES • Field tests of valves • Buttweld/socket weld end valves 1 ½” and less are exempt from field test Jerry Hernandez
Page 8
SAES-J-700, para. 9.2.1 SAES-J-700, para. 9.2.3 SAES-J-700, para. 9.3 SAES-J-801 SAES-J-801, para. 6.3.5 SAES-J-801, para. 7.3.2 SAES-J-801, para. 7.3.4 SAES-J-801, para. 7.6.2 SAES-J-801, para. 8.5 SAES-J-801, para. 10.4.1 SAES-J-901 SAES-J-901, para. 4.1.4 SAES-J-901, para. 4.3 SAES-J-901, para. 4.4 SAES-J-901, para. 4.5.2 SAES-J-901, para. 4.7.6.2 SAES-J-901, para. 4.8.1 SAES-J-901, para. 5.0 SAES-J-902 SAES-J-902, para. 6.1.3 (Table 1) SAES-J-902, para. 7.2 (Table 2) SAES-J-902, para. 11.1 SAES-J-902, para. 12.1 SAES-J-903 SAES-J-904 SAES-K-402 SAES-K-402, para. 4.1.1 SAES-K-402, para. 4.1.6 SAES-K-402, para. 4.3.1 SAES-K-403 SAES-K-403, para. 4.1.9
SAES-K-403, para. 4.2.1 SAES-K-403, para. 6.1 SAES-K-501 SAES-K-502 SAES-K-511 SAES-L-008 para. 4.7 SAES-L-008 para. 4.7.5
11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Welded bonnet valves 4” and less permitted in hydrocarbon services if approved by responsible operating dept. • Screwed bonnet valves not allowed in hydrocarbon/hazardous services unless bonnets are tack welded to the body….. • Union bonnet valves not permitted in hydrocarbon/hazardous services • Top entry valves required for critical valves to facilitate in-line maintenance • 2” and less THREADED/SOCKET WELDED valves to be Class 800 • Chainwheel operated emergency isolation valves or threaded body valves not permitted • Gate valves with back seats not to be installed with stems below horizontal except…… • Seal welding required for all threaded connections on valve bodies • Inside-screw-rising-stem (ISRS) and non-rising-stem (NRS) valves NPS 2 inch and smaller shall not be used in hydrocarbon services. • Check valves in sizes NPS 3 inch and above shall not be installed in vertical lines, unless specifically approved by the Chairman of the Valve Standards Committee. • Atmospheric vents/drains shall be plugged/blinded on discharge side • Instrumentation root isolation valves shall be gate valves • Valve Body/TRIM MATERIALS requirements • Hot tap limitations • Applicable CODES/STDS. for pressure piping systems • Definitions of General Terms (on/off plot, plot limit, flowline,etc.) • PIPING Standards REVISIONS not mandatory retroactively • Services excluded from ASME B31 PIPING CODE • Process piping to comply with ASME B31.3 as minimum • Transportation piping to comply with B31.4/31.8 • Numbering Structure of New Piping Standards L-Series • CODE BREAK & PLOT LIMITS • What are considered CRITICAL Piping/Equipment? • • • • • • • • • • • • • • • • • • • • •
Regulated Vendors List for Pipes and Fittings Regulated Vendors List for Valves Piping Material Specs Valve trim number designation Min. pipe size to be ½”NPS except tubing/piping in Category D fluid, etc. 1 ¼”, 2 ½”, 3 ½” &5” not to use except for equipment connections X-42 thru X-60 may be substituted for Grade B for repairs and maintenance ERW & HFI welded pipe (along with seamless pipe) permitted outside process plant limits per B31.4/31.8 Locknuts, street elbows, street tees and reducing elbows not permitted Use of DURABOLT for offshore/underground piping Materials containing ASBESTOS prohibited Use of Duplex SS limited to water service CS piping require PWHT under ff. services: caustic soda, MEA, DGA, etc. Saudi Aramco PIPING SERVICE CODES Line class index & cross-reference between new and old classes Double block valves for drains/vents (applicable to 900# rating and above) Safety shields over flanged joints for hazardous services Flange Materials SPECS Match flanges with pipe of unequal strength per ASME B16.5 & B31 codes Flange types/ requirements WN flanges with tapered hub are primary selection for flanged joints in metallic piping systems of 2” & larger
Jerry Hernandez
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SAES-L-008 para. 5.1.3 SAES-L-008 para. 5.1.4 SAES-L-008 para. 5.1.6 SAES-L-008 para. 5.2.3 SAES-L-008 para. 5.3.2 SAES-L-008 para. 5.6.2 SAES-L-008 para. 5.7.1 SAES-L-008 para. 5.7.2.1 SAES-L-008 para. 5.8 SAES-L-008 para. 6.3.5
SAES-L-008 para. 7.7 SAES-L-008 para. 7.11.1 SAES-L-008 Table 1 SAES-L-052 para. 4.0 SAES-L-100 SAES-L-100, para. 4.0 SAES-L-100, para. 5.5 SAES-L-100, para. 5.6 SAES-L-100, para. 6.2 SAES-L-100, para. 6.3/6.4 SAES-L-100, para. 7.0 SAES-L-100, para. 8.0 SAES-L-100, para. 9.6 (also see SAES-O-100) SAES-L-101 SAES-L-102 SAES-L-105 SAES-L-105, para. 4.2 Table 1 SAES-L-105, para. 5.4.1 SAES-L-105, para. 5.4.2 SAES-L-105, para. 5.4.3 SAES-L-105, para. 5.4.5 SAES-L-105, para. 5.5.2 SAES-L-105, para. 5.6.2 SAES-L-105, para. 6.1.3 SAES-L-105, para. 6.1.5 SAES-L-105, para. 6.3.2 SAES-L-105, para. 7.2.5 SAES-L-105, para. 9.0 Table 1 SAES-L-105, page 76 SAES-L-109, para. 4.5 SAES-L-109, para. 5.0 SAES-L-109, para. 5.6 SAES-L-109, para. 6.0 SAES-L-109, para. 6.1 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Slip-on flanges not permitted in severe cyclic conditions, etc. • Lap joint flanges also not permitted in severe cyclic conditions • Blind flanges are for end closures and not to be drilled for other connections such as drains, etc. • Flange facings requirements • Assembly of Raised face to ring joint companion flanges permissible if approved by CSD • Blinds/ Jackscrews requirements • GASKET REQUIREMENTS • USE OF PIKOTEK GASKETS • Spiral wound Gasket area not to be coated • Recommended WN FLANGE materials for general service • Bolting requirements • Welded joints requirements • Maximum size of Socket Weld joints • Socket weld axial gap between male/female components to be 3 to 1.5mm • Prohibited piping joints (caulked/soldered/brazed, etc.)/components in pressure piping system • Threaded joints requirements • Minimum number of pipe threads engagement • Seal weld up to first block valve… • Exceptions to Seal Welding • PTFE not to be used on Threaded Connections where seal welding is req’d. • Threaded/Socket Welding fittings, unions, bushings requirements • Threaded/socket weld fittings to be class 3000/6000 or higher • Pipe unions in hazardous services to be class 3000 threaded/socket forged steel • Threaded Bushings with one pipe size reduction not permitted/Flush steel bushing not permitted • Pipe plugs in metallic piping shall be solid bar stock • • • • • • • • • • • • • • • • • • • •
Miter elbows prohibited Branch connection requirements Vent/drain connections not allowed on TEES, Elbows and reducers Use of SPECIALTY/PROPRIETARY COUPLINGS Use of POSITIVE SEAL COUPLINGS limited to 12” onshore non hazardous service Piping Flexibility Analysis Requirements Piping Load Conditions Friction forces from Supports & Guides SIS REQUIRED for Piping and Pipelines Materials for Low Temperature Service Pipes/Fittings/Flanges in Wet Sour Service where SSC is possible to comply with NACE-MR0175-2002 Seamless linepipe, ERW pipe per 01-SAMSS-016 considered HIC RESISTANT Piping materials selection Max. FLUID VELOCITIES REQUIRED in CS Piping Determining CORROSIVE environments CORROSION CONTROL MEASURES Corrosion allowance required Determining CRACK-INDUCING ENVIRONMENT CRACKING CONTROL MEASURES Wall Thickness Requirement for CS pipe 4” & larger
Jerry Hernandez
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SAES-L-109, para. 6.4 SAES-L-109, para. 6.5 SAES-L-109, para. 6.6 SAES-L-109, para. 8.0 SAES-L-109, para. 8.4 SAES-L-109, para. 10.0 SAES-L-109, para. 11.0 SAES-L-109, para. 11.4/11.5 SAES-L-109, para. 11.6 SAES-L-109, Table 3 SAES-L-109, para. 12.0 SAES-L-110, para. 5.0 SAES-L-110, para. 5.2.1 SAES-L-110, para. 5.2.3 SAES-L-110, para. 6.0 SAES-L-110, para. 7.0 SAES-L-110, para. 7.4 SAES-L-110, para. 8.2 SAES-L-110, para. 8.3 SAES-L-110, para. 8.5 SAES-L-110, para. 10.0 SAES-L-110, para. 10.1 SAES-L-110, para. 10.2 SAES-L-110, para. 10.3 SAES-L-110, para. 10.7 (also see SAES-L-105, para. 5.5.5) SAES-L-110, para. 11.4 SAES-L-110, para. 12.0 SAES-L-110, para. 12.3 SAES-L-110, para. 13.0 SAES-L-110, para. 13.2.1 SAES-L-120, para. 6.0 SAES-L-120, para. 7.0 SAES-L-120, para. 7.7 SAES-L-125 SAES-L-130 SAES-L-132, para. 4.4.2 SAES-L-132, para. 4.4.3a/b SAES-L-132, Table 1 SAES-L-132, para. 5.0 SAES-L-133, para. 6.0 SAES-L-133, para. 7.0 SAES-L-133, para. 7.3 SAES-L-133, para. 8.0 SAES-L-133, para. 9.0 SAES-L-136, para. 5.3 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Restrictions on use of ERW, SPIRAL WELDED, CS & Iron Pipe Spec • Derate X70/65 to X60 for on plot piping • Sch 40 NPS 2” & Below only permitted in non hazardous service • RV required in fully blocked pipeline sections • Pressure test requirements • 100% X-RAY in lieu of hydrotest • Instrument Impulse Lines to be Leak tested • Pressure test not required on minor repairs deemed impractical to test but service test required • Weld-plus-ends pneumatic testing • On-plot piping design package includes P&ID, Iso's, etc. • Plant Piping Design Factors and Allowable Stresses • Pipe smaller than ¾” not permitted in hydrocarbon services except…. • Minimum STRUCTURAL Pipewall Thickness • Minimum pipewall thickness for CS pipes • Deadlegs requirements • Exemptions to Deadlegs • Pipe expanded joints not permitted regardless of service types • Pipe clearance between BOP and finished grade to be 300mm • Minimum 50 mm clearance between plant piping and any structures • Minimum cover for on-plot buried piping • Dummy supports requirements • • • • •
END ANCHORS requirements Intermediate anchors required at center of expansion loops/offsets Branches 4” & less to be 24” from any fixed obstruction WEAR PADS & SADDLES Drinking/Firewater systems prohibited to be connected to process equipment • Pipes shall not be stored directly on ground • Examples of non-pressure containing welded attachments • Flange alignment for in-plant piping construction • PWHT of piping spools with non-pressure containing attachment welds • ORIFICE FLANGES Requirements • Jackscrews required where SPEC plate is installed • Branch connections and their Reinforcements not to cover girth welds • Plant piping wear pads to have rounded corners • Pipe cleaning during pre-commissioning • Transition zones not to be encompassed by concrete or asphalt • Min. external coating extension of 1 meter at transition point • Plant Piping MARKING/PAINTING/INSULATION • B31.3 piping acceptable with B31.4/31.8 if approved by CSD • Cost effectiveness as basis for Pipe Sizing • Pipelines Design Factors & Stress Level • 0.5DF for flowlines 50m from SSD fence but not less than 150m from production header, and for pipelines within 150m of plant SSD fence • Pipelines WEAR pads to have rounded corners • Pipelines Wall Thickness Limitations • Buried P/L Top of Pipe to be 450mm min. below finished grade • Non-restrained pipelines require expansion offsets • Aboveground pipelines/BERMED OVER PLs require crossings at selected locations • Spacing of PARALLEL pipelines • Min. clearance between pipelines and any structures Jerry Hernandez Page 11
SAES-L-136, para. 6.0 SAES-L-136, para. 6.7 SAES-L-136, para. 6.10 SAES-L-140 para. 4.1 SAES-L-150 SAES-L-150, para. 5.7 SAES-L-150, para. 5.12 SAES-L-150, para. 9.1 SAES-L-150, para. 10.2 SAES-L-310, para. 7.0 SAES-L-310, para. 8.3 SAES-L-310, para. 10.2 SAES-L-310, para. 10.4 (Table 1) SAES-L-310, para. 10.5 (Table 2) SAES-L-310, para. 11.4 SAES-L-310, para. 11.4.4 SAES-L-310, para. 11.5.4 SAES-L-310, para. 12.3 SAES-L-310, para. 12.4 SAES-L-310, para. 13.3.3 SAES-L-310, para. 14.7 (also see SAES-L-350, para. 13.2 SAES-L-310, para. 15.1 SAES-L-310, para. 15.2 SAES-L-310, para. 12.5 SAES-L-310, para. 16.2 SAES-L-310, para. 19.10/19.11 SAES-L-350, para. 7.1 SAES-L-350, para. 8.4 SAES-L-350, para. 9.5/9.6/9.7 SAES-L-350, para. 10.3 SAES-L-350, para. 10.4 SAES-L-350, para. 10.5 SAES-L-350, para. 10.6 SAES-L-350, para. 11.3 SAES-L-350, para. 15.0 SAES-L-350, para. 16.4.1 SAES-L-350, para. 16.4.2 SAES-L-350, para. 20/21/22 SAES-L-410, para. 5.2 SAES-L-410, para. 7.1 SAES-L-410, para. 8.0 (Table 1) SAES-L-410, para. 8.4 SAES-L-410, para. 8.7.3 SAES-L-410, para. 11.6 (Table 3) SAES-L-410, para. 12.2 SAES-L-410, para. 12.5.3 SAES-L-410, para. 13.2 SAES-L-410, para. 13.3 SAES-L-410, para. 13.4 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Pipeline markers requirement • Buried P/L End Anchors Required • Intermediate Anchors Required • Camel Crossings not to be used as End Anchors • Ring girders pipe supports • PIPELINES CLEARANCE from FINISHED GRADE • Pipeline Support Spacing/Use of Guides & STOPS • Sectionalizing of long pipelines using block valves • Flowline isolation block valve required outside SSD fence • Check valves required in each branch at intersection point • Bypasses around the check valves shall be installed where there is a requirement for eventual pumping of water or other liquids from the GOSP to a well site. • Vents/drains on pipelines per Operations requirement • P/L SCRAPING REQUIREMENTS • Provide Scraper Traps where periodic scraping is required • SCRAPER TRAP Design Requirements • Long radius bends required in pipelines with scraping facility • Horizontal scraper traps to have sliding supports • 4” Min. distance between anchor rebar and sleeve to ensure CP of pipeline • Right of way (ROW) during and after pipeline construction • P/L Vents/Drains not req’d. unless approved • P/L Temporary Vents/Drains to be plugged and seal welded • Long radius elbows required in Pipelines • Pipe supports to be on stable base 1.8m dia. to prevent future settling • CP Bonding stations MAYBE required where pipeline crosses or comes near another buried line • Max. allowable unsupported length before backfilling • P/L Cover Requirements • LPG, gas & oil flowlines min. cover of 900 mm • Installation in Sandy Areas • 200 mm sand annulus around buried pipe required • 6” marl cover or crude oil stabilizing for sand retention • Half Trenching ALLOWED where economically justified • Top of BERM to be 2 X pipe diameter • Berm sides not be Steeper than 35 degrees • Installation Requirements in RIVERS/WADIS • THRUST BORING REQUIREMENTS • CASINGS to be used for RAILROAD CROSSINGS • Pipeline crossing to be near perpendicular to road • Pipeline protection against vehicle collision • TRAFFIC Load Classification • Steel casing wall thickness • Casing corrosion protection • Minimum cover for P/L crossings under Railroads & Highways • Non metallic piping not permitted in hydrocarbon services • Plastic piping to be shielded from UV rays • Threaded flanges not permitted in non metallic piping systems • Flanged joints in non metallic piping to be made with flat face flanges…. • Non metallic piping joints to be outside concrete anchor blocks • RTR piping is approved for Firewater Service • Non metallic piping DESIGN REQUIREMENTS • Transition from non metallic to metallic Jerry Hernandez
Page 12
SAES-L-410, para. 13.5 SAES-L-410, para. 14.1 SAES-L-410, para. 14.3 SAES-L-410, para. 14.4 SAES-L-410, para. 14.5 SAES-L-410, para. 14.6 SAES-L-410, para. 14.7/14.8 SAES-L-410, para. 15.0 SAES-L-410, para. 15.2 SAES-L-410, para. 16.1 SAES-L-410, para. 16.3
SAES-L-410, para. 17.1 SAES-L-410, para. 18.0 SAES-L-420, para. 4.1 SAES-L-420, para. 6.0 SAES-L-420, para. 7.5 SAES-L-420, para. 7.7 SAES-L-440, para. 7.4 SAES-L-450, para. 7.2 SAES-L-450, para. 9.1 SAES-L-450, para. 9.2 SAES-L-450, para. 10.2.1 SAES-L-450, para. 13.6 SAES-L-450, para. 14.2 SAES-L-450, para. 14.5 SAES-L-450, para. 14.6 SAES-L-450, para. 14.6.3 SAES-L-450, para. 14.8 SAES-L-450, para. 14.8.3 SAES-L-450, para. 14.8.5 SAES-L-450, para. 14.9.3 SAES-L-450, para. 14.9.3g SAES-L-450, para. 14.10.2 SAES-L-450, para. 14.11 SAES-L-450, para. 16.0 SAES-L-460, para. 6.2 SAES-L-460, para. 6.8 SAES-L-460, para. 6.9 SAES-L-460, para. 7.3 SAES-L-460, para. 8.3 (Table 1) SAES-L-460, para. 9.0 SAES-L-460, para. 10.3 (Table 2) SAES-L-610, para. 4.1.1 SAES-L-610, para. 4.1.5 SAES-L-610, para. 4.2.2 SAES-L-610, para. 4.3.1a SAES-L-610, para. 4.3.10 SAES-L-610, para. 4.1.2 SAES-L-610, para. 4.2 SAES-L-610, para. 4.3.2/4.3.3 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Riser Design Factor is 0.5 • Submarine P/Ls & Risers DESIGN Requirements • Use of Underwater Valves to be Avoided • Submarine P/Ls Coating Requirements • UNDERWATER WELDING PROVISIONS • Definition of ‘Building” • Saudi Aramco fence requirements • Coating required for steel in contact with insulation • Removable insulation plugs required for UT • Electrical grounding required • Concrete paving requirements • FBE coated rebars requirements • Min. required concrete cover • Aluminum conduits/pipes not to be embedded in structural concrete • Concrete placement requirements • Min. 7 days water curing for structural concrete • Use of plasticized vapor sheet barrier beneath slabs/foundations • Coat with coal tar all concrete surfaces in contact with earth • Top of concrete to be 6” above finished grade • Anchor bolt size min. 20 mm • Double nut on anchor bolt for uplifting/vibration protection • Anchor bolt/sleeve to be 4” from concrete surfaces • Foundations spacing for heavy machineries • Cement based non-shrink grout requirements • Epoxy grout requirements • Saudi Aramco Water Systems • Sprinkler and Standpipe Systems in Buildings • Saudi Aramco Plumbing Code • Plastic piping installation to be done only by qualified personnel • Trench width/min. cover for plastic pipe installation • Flange connections required for dissimilar piping materials • Thrust block required at every change of direction for RTR and thermoplastic • Thermoplastic pipe not to be in contact with concrete • Plastic piping hydrotest requirements • GTAW reqd. for all passes of butt welds in nozzles/piping less than 1” dia. • GTAW for root pass of butt welds on 2” or less • DMW not permitted for pressure containing welds in sour service • Buttering of weld joints
• •
SS and non ferrous materials to be cleaned with grinding wheels/SS brushes not used previously on other materials Tack welds to be done by qualified welders only
•
Peening prohibited unless approved by CSD
•
Back purging required for GTAW/GMAW on P5 materials or higher
•
Use of nitrogen as backing gas on austenitic SS prohibited
•
Seal welding requirements
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SAES-L-810, para. 4.2 SAES-L-850, para. 5.0 SAES-L-850, para. 6.2 SAES-L-850, para. 7.1/7.2 SAES-L-850, para. 7.6 SAES-M-001 para. 1.0 SAES-M-006 SAES-N-001 para. 7.1 SAES-N-001 para. 8.2.2 SAES-P-111 SAES-Q-001 para. 4.19 SAES-Q-001 para. 5.5 SAES-Q-001 para. 5.8 SAES-Q-001 para. 6.5 SAES-Q-001 para. 7.0 SAES-Q-001 para. 10.3 SAES-Q-001 para. 11.1/2 SAES-Q-001 para. 11.4 SAES-Q-005 para. 4.3.2a SAES-Q-005 para. 4.7.3 SAES-Q-005 para. 4.7.4 SAES-Q-005 para. 4.7.5 SAES-Q-007 para. 5.15 SAES-Q-010 SAES-Q-011 SAES-S-040 SAES-S-050 SAES-S-060 SAES-S-070 para. 8.0 SAES-S-070 para. 9.14 SAES-S-070 para. 15.1 SAES-S-070 para. 17.1 SAES-S-070 para. 17.4 SAES-S-070 para. 18.0 SAES-W-010, 011, 012 para.5.2.2 SAES-W-010, 011, 012 para.5.2.3 SAES-W-010, 011, 012 para. 6.4.2 SAES-W-010para. 11.3.4.1 SAES-W-011 para. 11.3.5 SAES-W-012 para. 10.3.5 SAES-W-010, 011 para. 11.4.3 SAES-W-012 para. 10.6.3 SAES-W-010, 011 para. 11.5.1 SAES-W-012 para. 10.9.1 SAES-W-010, 011 para. 11.12.1 SAES-W-012 para. 10.16.1 SAES-W-010, 011 para. 11.14.1 SAES-W-012 para. 10.18.1 SAES-W-010, 011 para. 11.14.4 SAES-W-012 para. 10.18.2 SAES-W-010, 011 para. 11.15 SAES-W-012 para. 10.19 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Preheat requirements •
PWHT requirements
•
Hardness test requirements
•
Welds may be repaired twice………
•
Cracked welds except crater cracks to be cut out
• • • •
Welding electrodes conditioning and storage requirements 4” min. offset distance between girth and long. welds 2 welders required for pipelines above 16” dia. Min. distance between parallel butt welds to be the greater of ¾” or 3x w.t.
•
Back welding may be used
•
Provide CP for all submerged and buried metallic marine structures, equipment and pipelines using galvanic anode systems, impressed current anode systems, or their combination Install an impressed current system where AC power is available Minimum design life for the cathodic protection systems shall be 25 years for galvanic and 20 years for impressed current… DC cables connected to the rectifier shall be AWG #4 (25 mm²) or larger. Energize all impressed current anodes within 30 days of installation Repair of anodes or anode cables is not permitted Cathodically protect all buried pipelines with impressed current systems Minimum design life of both impressed current and galvanic anodes systems shall be 20 years Anodes to be installed deeper than 15 meters shall be classified as "deep" anode beds, and… Use oil immersed rectifier units at all locations inside hydrocarbon plant areas, within 30 meters of a hydrocarbon plant perimeter fence (outside), or within 1 km of a coastline Install soil access test stations at 20 meter intervals in paved areas, directly over the pipeline At pipeline transitions through asphalt or concrete, provide 30 cm of unpaved soil around the transition, for potential monitoring Bonding requirements… Protect transformers, rectifiers, and photovoltaic power supplies located outside existing plant security fences from damage, with a type IV fence CP is required for the internal surfaces of metallic tanks and vessels if…. The minimum design life for galvanic or impressed current anode systems shall be either 7 years, or the testing and inspection (T&I) period, whichever is greater. Anode materials…. All buried D.C. cables (anode, bond, positive, and negative) shall be identified by cable route markers in accordance with Standard Drawing AB036351 Guardrails are required around unfenced rectifiers and junction boxes located inside plants and exposed to potential damage from vehicular traffic CP of Plant Facilities…
• • • • • • • • • • • • • • • • • • •
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SAES-W-010, 011 para. 12.0 SAES-W-012 para. 11.0 SAES-W-010, 011 para. 13.0 SAES-W-012 para. 12.0 SAES-W-010, 011 para. 14.0 SAES-W-012 para. 13.0 SAES-W-010para. 16.1 SAES-W-011 para. 18.1 SAES-W-012 para. 17.1 SAES-W-010para. 16.2 SAES-W-011 para. 18.2 SAES-W-012 para. 17.2 SAES-W-010, 011, 012 Table 1 SAES-W-012 para. 10.5 SAES-W-012 para. 10.7.1 SAES-W-012 para. 10.20.1 SAES-W-011 para. 11.16.1 SAES-W-012 para. 10.21 SAES-W-011 para. 11.17 SAES-X-300, para. 4.2.1
SAES-X-300, para. 4.2.2 SAES-X-300, para. 4.3 SAES-X-300, para. 4.8 SAES-X-300, para. 6.2 SAES-X-300, para. 5.3.2 SAES-X-400, para. 4.2.1 SAES-X-400, para. 4.3 SAES-X-400, para. 4.6.2 SAES-X-400, para. 4.7.1
SAES-X-400, para. 4.9.2 SAES-X-400, para. 4.9.3 SAES-X-400, para. 4.10 SAES-X-400, para. 5.8.1 SAES-X-500, para. 4.1.1 SAES-X-500, para. 4.3.1
SAES-X-500, para. 4.6 SAES-X-500, para. 5.4.2
SAES-X-500, para. 5.6.2 SAES-X-600
11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Onshore oil, gas, and water injection well casings with a life expectancy greater than five years shall be provided with impressed current cathodic protection • Well casings with backfilled cellars made from steel, steel reinforced concrete, or dielectric materials shall be provided with two prepackaged 27.5 kg (60 lb) magnesium anodes (17-SAMSS-006) installed inside each wellhead cellar to mitigate landing base corrosion • CP systems for well casings shall be commissioned within 6 months after the completion date of the well • Provide impressed current CP systems for bare steel reinforcement in existing concrete structures exposed to corrosive environment • Design the cathodic protection system for 40 years life or the remaining life of the structure, whichever is less • Custody transfer metering station for dry hydrocarbon gas service (natural gas and ethane rich gas • The metering station shall be skid mounted, fully automated system AND shall be designed for unattended operation and measurement. • Orifice plates requirements • Each meter station shall be equipped with isolating block valves located outside the meter skid. • Field instrumentation shall be provided for measuring the differential pressure, static pressure and temperature • Royalty Metering of Hydrocarbon Liquids • What is Royalty measurement? • Selection shall be limited to turbine meters… • Custody metering of hydrocarbon liquids • Process Control Systems • Pipelines Leak Detection System • Process Automation Networks (PANs) Connectivity • EIS preparation - Responsibilities • Max. T&I interval for Saudi Aramco EQUIPMENT • Subsequent OSI intervals shall not exceed the max. intervals per Table II. • EIS Deviation/T&I Extension • EIS Revision • An annual T&I summary report shall be prepared by the responsible Operations Inspection Unit, signed by the facilities' Operations Engineering Superintendent and transmitted to the Operations Inspection Division of the Inspection Department by January 31 of each year. • Standard Drawings are mandatory to the extent indicated by specific Saudi Aramco Engineering Standards (SAESs) and Saudi Aramco Materials System Specifications (SAMSSs). • SAMSSs are material or equipment specifications that establish minimum engineering, design, fabrication, and testing requirements for procured material or equipment and cover material or equipment that are procured on a repetitive basis. • SAESs are generally not applied retroactively to the maintenance and repair of existing facilities unless there is HSE impact… • PAS Obsolescence Criteria • Basic purpose of an SAER (Saudi Aramco Engineering Reports)? • Instructions for obtaining WAIVERS • "After-the-Fact" Waiver Request • Library Drawings differ from Standard Drawings, being not mandatory and.. • SAEP-306 only for piping designed to ASME B31.4/31.8 • Metal loss on fittings not in SAEP-306 scope Jerry Hernandez
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SAES-X-700, para. 1.2
SAES-X-700, para. 1.4
SAES-X-700, para. 6.1.1 SAES-X-800, para. 1.0 SAES-X-800, para. 5.1 SAES-Y-101 SAES-Y-101, para. 7.2 SAES-Y-101, para. 8.0 SAES-Y-101, para. 13.1 SAES-Y-101, para. 15.1.1 SAES-Y-102 SAES-Y-102, para. 1.0 SAES-Y-102, para. 4.4.1 SAES-Y-103 SAES-Z-001 SAES-Z-003 SAES-Z-010 SAEP-20 para. 4.0 SAEP-20 para. 5.5 Table I & 5.5.9 SAEP-20 para. 5.5.6 Table II SAEP-20 para. 5.8 SAEP-20 para. 5.9 SAEP-20 para. 5.10
SAEP-110, para. 3.1
SAEP-119, para. 3.1
SAEP-125, para. 3.1 SAEP-135, para. 3.1 SAEP-201, para. 1 SAEP-302, para. 3.0 SAEP-302, para. 3.3 SAEP-305, para. 1.1 SAEP-306, para. 1.0 SAEP-306, para. 3.1.4 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Non-corrosion damage, such as cracks, dents, gouges or grooves, shall be identified and reported to the Responsible OED or CSD for evaluation. • 10% rule on press. Design thickness with pipe still maintaining integrity • Evaluate strength of corroded pipelines • Insp. Dept. audits autonomous Insp. Units • Abqaiq Plants Ops. Eng. Insp./Corr. Unit shall inspect Community Facilities in Al-Farhah and Abqaiq main camps, Abqaiq bulk plant (PLT279) in Abqaiq Community Industrial area, Industrial & Management Training Centers and Operation Support Facilities in Al-Farhah and Abqaiq main camps. • SACCID/INSP. is responsible for community facilities in Udhailiyah, Mubarraz/Al Hasa area and at the Qurayyah Aramco Beach Facility. • Uncovering U/G sections limited to 15.24 m separated by buried sections of equal length • 400 mm working clearance for P/L repair • • • • • • • • • • • • • • • • • • • • • • • • • • •
About Pyrophoric materials All mechanized repair equipment to be located upwind Maximum allowable welding press. to avoid weld blow out USE Low hydrogen electrodes FOR WELDING ON LINES UNDER PRESSURE No welding on compressed air lines Flow is required during welding ‘No flow’ situations to be approved by GS Ops. Engineering and Ops. Supt. For a pipeline crack, rupture or any other case which cannot be repaired by hot tapping, patching or sleeving, the failed section shall be removed by cold cutting and a replacement section installed. Minimum length of replacement section (insert) to be not less than 2D Length of transition or pup pieces welded to other pipe, fittings or valves to be 6” or longer Steel tapered plugs (for repair) not permitted on normally scraped lines Full encirclement sleeves to use on leaking lines or on lines below pressure design thickness Backing strips required on sleeves with longitudinal butt-welded seam Minimum length of repair sleeve to be 4” (no maximum length) Sleeve thickness required Repair of Surface Defects and External Corrosion Repairs of HIC in pipelines Required repairs on internally coated lines It is permitted to weld across an existing long., spiral or girth weld seam of the P/L. Required welding sequence on repair sleeves A minimum of two (2) magnesium anodes shall be used for supplemental cathodic protection. Installation of Hot Tapped connections No hot tap permitted when HIC or lamination is evident The hot tap machine shall have Pressure test once every four months and overhaul once every 12 months. A body and high pressure seat test (on both sides of the seat) shall be performed in the shop on all hot tap valves prior to installation. After installation of the branch connection, but prior to installing the reinforcing pad or full encirclement ring, a full hydrostatic pressure test shall be applied to the branch connection. A pneumatic test of 173 kPa (ga) (25 psi) shall be applied to the reinforcing pad or ring after installation.
Jerry Hernandez
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SAEP-306, para. 3.2.3 SAEP-306, para. 3.3.2 SAEP-306 SAEP-308, para. 1.0 SAEP-309, para. 4.6
SAEP-309, para. 4.7 SAEP-310, para. 3.1.2.3 SAEP-310, para. 3.1.2.4 (SAES-W012) SAEP-310, para. 3.1.4.1.3 SAEP-310, para. 3.1.4.1.5 SAEP-310, para. 3.1.4.5 SAEP-310, para. 3.1.4.5.6 SAEP-310, para. 3.1.4.5.7 SAEP-310, para. 3.1.4.5.10 SAEP-310, para. 3.1.4.5.11 SAEP-310, para. 3.2.2
SAEP-310, para. 3.2.2.3.1 SAEP-310, para. 3.2.2.3.2 SAEP-310, para. 3.2.3.1.1 SAEP-310, para. 3.2.3.3.1 SAEP-310, para. 3.2.3.3.2 SAEP-310, para. 3.2.3.3.2 SAEP-310, para. 3.2.3.3.3 SAEP-310, para. 3.2.4 SAEP-310, para. 3.2.5 SAEP-310, para. 3.2.7 SAEP-310, para. 3.3.1.3 SAEP-310, para. 3.3.3 SAEP-310, para. 3.7.2 SAEP-311 SAEP-311, para. 3.5.7 SAEP-311, para. 3.8.2.1 SAEP-311, para. 3.8.6 SAEP-311, para. 3.8.7
SAEP-311, para. 3.8.8 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • Use of weld plus ends couplings • Use of PLIDCO split sleeves • Use of PLIDCO repair clamps • Installation of stopple fittings • All coating applicators to be certified • T & I of Shell and Tube Heat Exchangers • RV installation/deletion/changes • Dhahran OID responsible for overall administration of RV program • Each RV shall be identified by attaching a corrosion resistant metal tag FIRMLY secured by a 16 gage stainless steel wire. • The RV number shall be die stamped on the body of screw type valves, on the outlet flange of flanged RVs. Also, stamping of the mating pipe flange or installing a field RV number tag is recommended to avoid installation errors. • All other RVs shall be painted with the mandatory aluminum color, as per SAES-B-067. • TEST RVs used for PRESSURE TESTING shall be identified with a corrosion resistant metal tag and… • A RV in a mothballed facility shall remain in SAP system under Relief Valve equipment category and... • RV routine T&I and Maintenance • The MAXIMUM TEST INTERVAL shall be 36 months except… • A RV shall, as a minimum, be shop disassembled at every third test interval for an internal inspection. • CSD issued Technical Alert 16/94 (Alert16) which requires the integral RVs in Grove Model B-5 ball valves to be replaced… • Intervals for RVs in Mothballed Facilities… • As a minimum, PRESSURE TEST RVs shall be DISASSEMBLED annually. • RV shop disassembly shall be required when… • After each successful T&I, an external inspection on a RV shall be conducted by Inspection Unit to ensure proper installation and identification. • An In-place RV T&I shall be approved when it is feasible and safe to adjust a RV on line, and the RV has satisfied the disassembly requirements. • SAUDI ARAMCO welders certification • Contractor Welders certification • Inspection Requirements for Pressurized Equipment • RBA FOR IN-PLANT STATIC EQUIPMENT • Minimum requirements to assemble pressure containing bolted flanged joints including bolt tightening… • HIPS - When should they be considered or applied? • Pressure Relief Valve Conventional and Balanced Types • During every T & I, inspect lube/seal oil and fluid power systems to determine the need for chemical cleaning. • Weld Test Supplements • Use of Form 3099A RV Authorization • Use of RV test stand • RV TECHNICIAN CERTIFICATION • OSI ADMINISTRATION • SAUDI ARAMCO NDT Personnel certification • CONTRACTORS NDT Personnel certification • RADIOGRAPHIC EXAMINATION • MAGNETIC PARTICLE EXAMINATION Jerry Hernandez
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SAEP-312 SAEP-313 SAEP-314 SAEP-315 SAEP-316, para. 3.1 SAEP-317 SAEP-318 SAEP-318, para. 6.1 SAEP-318, para. 9.1 SAEP-318, para. 9.3
SAEP-318, para. 9.6 SAEP-318, para. 12.3 SAEP-318, para. 13.0 SAEP-319 SAEP-319, para. 5.2 SAEP-319, para. 5.2.1 SAEP-319, para. 5.2.3 SAEP-319, para. 5.6 SAEP-319, para. 5.7.2 SAEP-319, para. 7.9 SAEP-319, para. 7.18
SAEP-319, para. 10.1 SAEP-321 SAEP-323 SAEP-325 SAEP-343 SAEP-351 SAEP-354, para. 4.1 SAEP-1027 SAEP-1028 SAEP-1101 THRU 1117 SAEP-1131 SAEP-1132 SAEP-1134 SAEP-1135 SAEP-1140 SAEP-1142 SAEP-1143 SAEP-1144 11/28/2005
QUICK GUIDE TO SAUDI ARAMCO STANDARDS AND PROCEDURES • PENETRANT EXAMINATION • MANUAL UT TESTING • Inspection Department is responsible on all capital projects managed by or for Saudi Aramco. • Approving ready-mixed concrete mix design to avoid redundancy of reviewing previously accepted mixes… • ELECTRICAL INSPECTION • SMALL PIPE NIPPLE INSPECTION • RETIREMENT THICKNESS OF IN-PLANT PIPING • Saudi Aramco procedure for hydrotesting flexible piping… • Inspection and evaluation instructions for the installation of the HDPE (High Density Polyethylene) molded flange/pipe liner... • Inspection of Positive Seal Coupling Systems • Inspection requirements for use of metal studs in buildings… • Inspection Procedure for Conduit/Cable Trays • Inspection requirements prior to and during installation of PVC coated rigid steel conduits. • Inspection and the witnessing of specific tasks performed during the routine scheduled maintenance of GRAM type high voltage oil switches rated 2.4 kV to 34.5 kV. • Inspection guidelines to be followed for the installation of Cathodic Protection Deep Anode Beds… • Inspection of AIR-COOLED HEAT EXCHANGERS • Guidelines of conducting HAZOP • Guidelines for acceptance, alarm, and shutdown vibration limits for rotating equipment throughout Saudi Aramco… • Corrosivity of multiphase system • Concrete Repair Manual
Jerry Hernandez
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SAEP-1145 SAEP-1146 SAEP-1150 SAEP-1152 00-SAIP-51 01-SAIP-01 01-SAIP-02 01-SAIP-05 01-SAIP-07 02-SAIP-01 12-SAIP-50 15-SAIP-50 15-SAIP-51 16-SAIP-11
17-SAIP-50 32-SAIP-11 SAER 5437 SAER 5659 SAER 5686 SAER 5803
11/28/2005
