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
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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
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MATREIAL 12LC0U Steel pipe ASTM A53, API5L Grade B 12FE0U RTR Fiber Glass AWWA C950 FIBERGLASS PRESSURE PIPING
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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 ½- 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
