GUIDE FOR TESTING QC CANDIDATES (UG PIPING/HYDRO/WELDING) ADD SATIPS FOR UG PIPING TO THIS LIST & SAICs FOR PUNCHLISTING ADD PLANT FIREWATER SAES-B-017/019 & SATIPs ... Section 12.6 ADD SATIPs SAES-S Series (S-010, 30, 40, 50, 60, 70 all) SATIP-L-350 related to UG Piping (Understands connection) Have copies of other applicable piping/hydro standards at Test site, have open book discussion forum with candidate. Allow candidate time and stress the importance of using “Scope” & “Index” when referring to Standards or searching for references. USE PLANT PIPING CHECKLIST AS REFERENCE FOR TEST & ISO drawing Test Identify the lowest point elevation on all drawings Identify any Mark Numbers on drawings (samples given) Identify any unusual features or items to be removed for hydrotest On each Drawing, list the following at the bottom of the drawing: Line number Piping Class Flange ratings Gasket types Limiting Factor for Hydrotest Medium for testing SAES-A-004 (Pressure Testing) SAES-L-105 (Piping Material Specifications) o Line Class Designators Where are the Saudi Aramco Line Class Designators and Service Codes. See Sect. 7, have candidate break down example of 6”-CA-127-1CS3C.
6” = Line Size, CA = Caustic Service, 127 = Line Identification #, 1 = Pressure Rating @ 150#, CS = Mat’l, 3 = Corr. Allow 4.8mm, C = Service (Caustic) SAES-S-020, 030, 040, 050, 060, 070 SAES-L-150 (Testing of Plant Piping) GI 2.102 Pressure Testing Safely Pre-Punch Checklist 1. Lay-up procedure and estimated service date has been determined (60-day rule). 2. Line completed and in compliance with SA standards & Isometrics (as built or redlined dwgs available during punching). 3. System boundaries have been clearly identified and temporary blinds have been installed per hydro test diagram. 4. Correct Construction Materials utilized (grade/schedule). Color-coding (green). 5. Correct rating of materials (flanges, forged fittings). Determine test limitations (psi). 6. Branch reinforcement meets SA standards and TPSA piping specifications. 7. Piping installed plumb and level, slope angle correct where required. 8. Weep holes and vent holes in reinforcement and wear pads. Air testing completed, OK. 9. Valve types, location and orientation correct. 10. Correct bolts installed and identified. Stamping of hardware meets specifications. 11. Temporary gasket locations have been identified for gasket reinstatement on dwgs. 12. Correct gasket type, size and rating. Reports/dwgs for Gasket installation accepted. 13. Color-coded marking on hardware by QC has identified final torque acceptable.
14. Permanent supports and guides are installed. Temp. Supports (if needed) installed. 15. Water quality analysis requirements for flushing/testing 16. High point vents fully opened prior to and during filling to remove air from the system. Low point drain available and identified. 17. Pressure gauges installed (2 minimum), with relief valve calibrated as required for 5% over pressurization. General Information What is an Inspection & Test Plan? A mandatory item in the Quality Plan that guides and assures quality in a specific type of work in a specific sequence of QC activity steps. What is a Quality Control procedure? A document that details the specific steps needed to fulfill the QC activity in the ITP What is a Quality Control Form? A written documentation detailing a specific activity in the ITP & QC Procedure What references will be found in ITPs? SA STDs, Procedures and code references, specifications What is a specification? A specification is a guideline to assure that minimum quality standards are met What 4 types of Inspection Action points are found in the ITP? Hold, Witness, Surveillance, Review Explain the differences between the 4 types of Inspection points? Detail answer and ensure a clear understanding by candidate What is a P&ID? Piping and instrument Diagram will show the piping layout and detailed notes relating to piping and instrumtation. What is an SIS? Safety Instruction Sheet that gives full design details related to a piping system or line. What is a piping system? Describes the specific service or fluid.
What is the piping line class designation? A specific name in alphanumeric designation describes features of a piping system. Give an example of a line designation from Isometric Drawing? 1CS1P3 = 150# class, Carbon Steel, 1/16” CA, General Hydrocarbon What is an isometric drawing? A detailed piping system/line drawing with reference to construction and material requirements What things are found in a Piping Isometric drawing? Line conditions, references to drawings, materials of construction, continuations, orientation, piping and drawing details and notes, revision control and approval status. What is a Material List or Material Take-Off Sheet (MTO)? Details of materials used in construction of Isometric. What is a PIP? Process Industry Practice details requirements for fabrication as Industry Practice. These are often the basis for SA stds Give an example of a PIP? PNSC 0001, PNSC 0011, PNSC 0021 What kinds of information and requirements are found in PIPs? Common industry practices for manufacture & construction Name the different types of Service Conditions? Temperature, pressure and fluid type Material Inspection Match physical condition in field to service condition shown on ISO/P&ID/SIS How do you verify (name several items to check) that the correct piping material is used? Mill Cert, heat number, color-coding & PMI, schedule, rating, Carbon Equivalent value for PREHEAT, diameter, class, grade. How do you identify fittings and flanges? Correct ratings, sizes, class, schedules as marked on fittings & mill certs
How do you check piping for the correct schedule? Use a Vernier Caliper and ensure piping is within tolerances. What are the tolerances for physical piping straightness and defects? Check the ASTM or API piping specification. What is the standard mill tolerance for piping? 87-1/2% (all) to 115% (greater than 2”), 120% (2’’ & less) of nominal Valves of the correct rating and material. Check materials, CMTRs & trim during Valve Testing (Visual inspection) Ovality What is the tolerance for ovality of RTR piping? How can piping stacked too high be damaged? Flanged Joints (SAES-L-050, PIPs PNSC series, Checklists, PFI-ES-3) Describe good inspection practice during gasket installation? List common problems associated with poor practice. Gasket installation checklist approved is the correct answer. Detailed discussion to follow. What is the requirement for bolting and torqueing flanges at SA? SAES-L-050, Tables and applicable procedure What is a friction factor? What is the difference between torqueing CS and SS bolting? Yield strength is greater in Carbon and torque values are greater Does the use of galvanized bolts require any special torqueing consideration, or can the CS bolt torqueing values be used? What is a spectacle plate? Mandatory SA Std dwg with plate used for service and shutdown (isolation) for maintenance purposes What are jackscrews and when are they required? They are located at flanged connections to facilitate maintenance and removal of spectacle and orifice plates to facilitate maintenance
Flange tolerances during construction are found where? SAESL-050 & PFI-ES-3. Describe how flanges can be misaligned in different directions? Rotational offset & hole misalignment, misaligned vertically & horiz What is cold spring? Application of mechanical stress (bending twisting pulling) upon a piping segment to achieve bolting and connection to another segment. Is cold spring acceptable? No How can an inspector determine if cold spring exists visually on a flanged section of piping? Visual determination is easy. Close inspection of flanged connection and any visible deformation, especially in small diameter sections. Clearances (SAES-S-070) REVIEW closely for obvious violations before piping construction Candidate must be able to discuss easily clearances required in SAES-S-070
