QA/QC MATERIAL FOR FRESHERS

2. Abbreviations
ASTM-American Society for Testing and Materials
ANSI - American National Standard Institute
API-American Petroleum Institute
ASME- American Society of Mechanical Engineers.
SAES – Saudi Aramco Engineering Standard.
SAMSS- Saudi Aramco Material System Specifications.
SAEP – Saudi Aramco Engineering Procedure.
SATR – Saudi Aramco Test Report.
SAIC – Saudi Aramco Inspection Checklist.

3. DUTIES AND
RESPONSIBILITIES OF
PIPING INSPECTOR
The duty of a Piping Inspector is to ensure all
Piping activities are carried out including
Material Receiving Inspection, Fabrication,
Erection, Line Checking, Testing and Re-
Instatement in strict accordance with
SAUDI ARAMCO Specifications and
Procedures

4. GENERAL
INSPECTION
The QC Inspector will make sure that the
inspection is carried out as per,
• Schedule “Q”
• SAUDI ARAMCO Standard & Specifications
• Approved Procedure & ITP.

5. GENERAL
Piping construction works shall be carried out
according to the following drawings.
– Plot Plan
– Piping General arrangement drawings
– Standard Pipe Support
– Drawings for Typical Detail
– Piping Hook-up drawings for instrument and processes.
– Line Schedule
– Piping & Instrumentation diagram
– Isometric Drawings
– Approved spool drawings

6. 1. MATERIAL RECEVING
INSPECTION

7. DURING MATERIAL RECEIVING
 QA/QC Inspector will verify that all material received shall meet the
acceptance criteria specified in the Purchase Order for the respective
materials.
 All material shall conform to the relevant material standards. The
Material Certificate shall verify the requirements as a minimum that
all components are properly marked with the following information.
 Material Specification / Identification / Heat No. / Material Grade
/ Item code number.
 Wall thickness / Schedule / Diameter.
 Color coding as per Project Specification.
 Piping Inspector shall be responsible for all material issued to NSH
and preparing Material Receiving Inspection Report for all Piping
Materials.
 If the materials are rejected during the Inspection, the material shall
segregated and tagged with “ Rejected” mark and it will be reported in
the Prescribed format ( Discrepancy Report) to the MC who shall
notify TRG / YERP MC for corrective action or replacement.

8. DURING MATERIAL RECEIVING
 All pipe and fittings shall have the material specification
and grade stamped, stencilled, or otherwise clearly
marked with permanent marking method.
 All pipes, fittings, flanges, valves and gaskets material
shall be sourced from Company approved manufacturers
and shall comply with the applicable Company and
Industry Specifications. This should be confirmed through
proper material identifications and certifications.
 Material substitution shall not be made without prior
approval from the engineering, PMT and Inspection
agency. Material Engineering Specialist should be
consulted as needed.
 All the Documents and Record in connection with
Materials shall be maintained for traceability.
 Check and verify the Identification tags on the materials.

9. Types of Fasteners
• Carbon Steel –ASTM A193-B7
• Stainless Steel –ASTM A-B8
• LTCS –ASTM A320-L7
• Alloy-ASTM A193-B16
• Hex. Bolt Structure Steel - ASTM 325
• Machine Bolt (RTRP) – ASTM A307 Grade A/B, ASTM 593 2H
• Stud Bolt
• U-Bolts
• Anchor bolts
• Hilty Bolts

10. STUD BOLT HEXAGONAL BOLT
ANCHOR FASTENER U-Bolt
HILTY
ANCHOR

11. Types of Valves
• Plug Valve
• Gate Valve
• Globe Valve
• Ball Valve
• Check Valve
• Butterfly Valve
• Needle Valve
• Control Valve
• Pressure Safety Valve
• Breather Valve

12. BALL VALVE GATE VALVE
GLOBE VALVE CHECK VALVE

13. BUTTERFLY VALVE NEEDLE VALVE
CONTROL VALVE PLUG VALVE

14. PRESSURE SAFETY VALVE
BREATHER VALVE

15. Pipe Schedules
• 5s
• 10s
• 20
• STD
• 30
• 40
• 40s
• 60
 Class 125
 Class 150
 Class 300
 Class 600
 Class 900
 Class 1500
 Class 2500
Ratings
 80
 XS
 80S
 100
 120
 140
 160
 XXS

16. Types of Fittings
 90 Degree Elbow
 45 Degree Elbow
 Concentric Reducer
 Eccentric Reducer
 Concentric Swage
 Eccentric Swage
 5D bend
 Cap
 Stub End
 Equal Tee
 Reducing Tee
 Coupling
 Lateral
 Thredolet
 Weldolet
 Sockolet
 Nippolet
 Elbolet
 Union
 Plug
 Strainer
 Pipe Nipple
 Expansion Bellow

17. 90 DEG ELBOW 45 DEG ELBOW
CONCENTRIC REDUCER ECCENTRIC REDUCER

18. CONCENTRIC SWAGE ECCENTRIC SWAGE
5D BEND BUTT WELD CAP

19. STUB END EQUAL TEE
REDUCING TEE FULL COUPLING

20. LATERAL THREADOLET
WELDOLET SOCKOLET

21. NIPPOLET ROUND PLUG
Y- STAINER PIPE NIPPLE PLAIN BOTH END

22. PIPE NIPPLE THREADED
ONE END
PIPE NIPPLE THREADED
BOTH END
EXPANSION BELLOW

23. Types of Flanges
 Weld neck
 Slip-on
 Lap-Joint
 Orifice
 Blind
 Socket Weld
 Spectacle Blind / Fig.8

24. WELD NECK FLANGE LAP JOINT
SOCKET WELD FLANGE ORIFICE FLANGE

25. BLIND FLANGE SPECTACLE BLIND / Fig. 8

26. Types of Gaskets
Spiral wound
O-Ring
Rubber
Neoprene
Graphite
Teflon

27. SPIRAL WOUND GASKET O-RING
NEOPRENE GASKET
TEFLON GASKET

28. SAMPLE SPOOL

29. 2. MATERIAL HANDLING &
STORAGE

30. MATERIAL HANDLING & STORAGE
 Maximum care shall be taken during the transportation and handling of
Pipes, Pipe Fittings, Valves, Gaskets and Piping specialities.
 Pipe shall not be stored directly on the ground. Pipe shall be placed on
wooden planks or sleepers minimum height of 100mm.
 Stacking of pipes shall be made in a manner to avoid damage to pipes or
coatings.
 All materials shall be handled with care installation to prevent damage.
 End protectors on pipes, flanges, weld bevels, threads, and socket ends
shall be firmly attached to avoid foreign particles entry.
 Pipe shall not be rolled or dropped off trucks.
 End bevel protectors shall remain on pipes and fittings while in storage,
protectors shall not damage internal or external coating.
 Flange face and threads shall be protected from rust by applying suitable
rust preventives.
 After completion of pre-fabrication, the spool shall be cleaned and free
from weld spatters, arc strikes and foreign materials on outside and
inside of pipes.
 Spool piece should be numbered with compatible material for painting
system at least on one place of each spool.

31. MATERIAL HANDLING & STORAGE
 All spools shall be clearly marked to easily identify the following as a
minimum:
 Area Code
 Line Number or Isometric No.
 Spool Number, Painting system, Heat No., Line class, Material colour
code.
 When a length of pipe is cut from a longer joint of pipe, all vendor
markings and other identifying information shall be transferred to each
length of pipe.
 All fasteners (bolts, nut, studs) found been rusted shall be preserved with
suitable rust preventive coating.
 Stainless steel, Alloy steel Pipes, Flanges and Fittings shall be handled,
transported and Stored separately.
 Extreme care will be taken to prevent contamination, damage and
corrosion to surface of the Pipes, Fittings and Valves.
 Nylon belts will be used for Lifting purpose of the Piping materials.
 Small materials, Instruments and Special items shall be stored in a
container and classified in accordance to Type, Material and Size
Identification shall be attach in front of each Materials.
 Unidentified Materials shall be kept on “HOLD” and segregated until it is
undoubtedly verified and Identified. (PMI) shall be carried out as per
YERP Procedure and Specification if required.

32. 1. Piping Materials
 A-Small tube to instrumentation Warehouse On rack
 B- Fittings Open storage on pallets (8" and above)
 C- Flanges Open storage on pallets (8" and above)
 D- Manually operated valves Open storage on pallets (4" and
above)
 E- Automatic valves Warehouse On pallets
 F- Bolts, Nuts and Washers Warehouse On rack / Oil drums
 G- Gaskets Warehouse On rack
 H- Spring hanger Warehouse On pallet
 I- Welding rod / electrode Warehouse On rack
Classification of Storage

33. SAMPLE MATERIAL STORAGE

34. 3. FABRICATION

35. PIPING INSPECTOR
Piping Inspector is responsible to inspect all
the Piping materials and dimension check prior
to fabrication. He inspects the beveled ends
and giving clearance for fit-up. He is also
responsible for Calibration of all Instruments /
machines using for Piping works.

36. Piping Inspection Tools

37. CUTTING

38. FABRICATION
CUTTING :
 Before cutting any pipes, heat number / ident. Codes shall
be transferred to cut piece for identification.
 Cutting of non-galvanized carbon steel pipe shall be done
by means of mechanical tools.
 Cutting of austenitic stainless steel materials shall be done
by mechanical tools, sawing, abrasive discs or plasma arc
cutting. No flame cutting shall be used for this purpose. If
SS is used for oxygen service plasma cutting is not allowed.
 Cutting shall be performed perpendicularly to the piping
component centerline unless otherwise indicated in the
drawings.
 All tools used for Stainless Steel shall be marked and care
will be taken to prevent that tools used for CS shall not be
used for Stainless Steel.

39. FIT-UP:

40. FIT-UP :
 Check drawings are Approved (IFC) before Fit-Up and they are of correct revision.
 Check Welding procedure specification and welder approval.
 Bevelled end shall be grinded to bright metal with a minimum metal removal of
2mm to ensure complete removal of surface contamination.
 Oil, moisture, rust, scale, sand, paint metallic coatings (e.g., zinc), or other foreign
matter shall be removed from the weld surface and at least 25 mm (1 in) of
adjacent base metal prior to welding, including any such coatings on temporary
attachments or supports.
 All tack welds shall be made by qualified welders.
 All tacks or temporary welds shall be performed with the same care,
materials, electrodes, minimum preheat, and procedures that are used
for permanent welds.

42.  Tack welds shall be of sufficient size to maintain joint alignment. The
recommended tack thickness is 3.2-4.8mm and length is 12.5–25.4mm.
the minimum number of tack welds are:
a) Pipe diameter of 101.6mm or less: three equally spaced tacks.
b) Pipe diameter above 101.6mm: minimum of four equally spaced
tacks. The designated inspector should determine if more tacks are
needed.
 Tack welds that are to be incorporated into the final weld shall be
thoroughly cleaned, prepared at each end, and inspected for cracks.
any cracked tacks shall be removed before welding the joint.
 Bridge tacks (located above the root area) are acceptable but such tacks
must be made completely within the weld groove and shall be
completely removed prior to completion of the weld.
 Any temporary welded attachments or temporary tack welds shall be
ground off. Attachments may be cut off no closer than 3 mm to the base
metal surface, prior to the required grinding.

43. FABRICATION
 SPOOL FABRICATION:
 Marking shall be done according to drawing requirement and the same shall be checked by
concerned supervisor prior to cutting.
 The cutting shall be generally done as follows:
Carbon Steel pipes - By gas cutting & grinding.
Alloy Steel pipes - By grinding or flammable cutting.
Stainless Steel Pipes - By grinding or plasma cutting (Except
Oxygen Service).
 Before cutting the pipe Heat Number shall be transferred to the cut pieces by low stress dye
stamping, Paint marking or Tagging.
 End preparation and fit-up shall be done at shop as per the approved YERP Specification
(SAES and approved WPS.
 Care shall be taken to make sure that longitudinal seams on the joining pipes will not come in
one line in a butt joint. Seams will be staggered at least 100mm apart and also will clear the
branch connections. Care shall be taken to make sure that longitudinal seams are not resting
on the steel structure and pipe support.
 Pipes and Fittings for fit-up will be placed on temporary pipe bed and will make sure that
supports are secured properly.
 Welding of the joint will be done after getting NSH QC fit-up Inspection clearance and the
same shall be offered for TRG inspection randomly as per approved ITP. All flange connected
to equipment shall be tack welded only.

45. FABRICATION Line No, Component Heat No., Joint No., Fit-up inspection signature, Welder No., Visual
inspection signature and date of welding will be marked near to the joint with metal paint
marker.
 Spool No. will be marked with paint marker and aluminum tag will be tied to the spool.
Fabrication completed spools will be shifted from shop to lay down area.
 NDT shall be performed as required by YERP specification. After NDT clearance, spools shall
be released for erection / painting with release notice.
 NDT rejected spools will be identified and kept in separate location with yellow & black tag
and the repair will be done immediately and NDT will be executed on repaired weld areas as
required. After painting, field inspection shall be offered for TRG QC and the same shall be
QC recorded in the prescribed format of approved procedure.
 After painting inspection, the spool shall be released for erection.
 Stainless Steel fabrication will be done in the shop with an isolated area from carbon steel
and alloy steel.
 No tools, tackles, equipment will be used for SS which has been used for CS. All tools and
equipment dedicated to SS work shall be clearly marked "For Stainless Steel" only.
 For Stainless steel materials, stainless steels tools will be used for grinding, brushing and
clamping etc.
 Pre heating and PWHT will be done at shop and field as per specification requirements and
approved WPS.
 All flanged raised faces of completed spools will be fitted with plywood blinds for protection
and spool ends shall be fitted with proper caps.

46. FABRICATION
PIPE SUPPORT FABRICATION:
 All supports, anchors, guides and other support attachments shall be fabricated in
accordance with details indicated in the pipe support drawings, isometric drawings
and manufacturer requirements, etc.
 Fit-up & welding shall be done at shop as per the approved SAUDI ARAMCO
Specification and approved WPS.
 Separate storage facility shall be made to store fabricated supports in area wise and
material wise,
 Fabricated CS, AS and SS supports shall be placed separately with proper
identification like type of support, sequence No etc. with legible marking.
 After painting inspection, the support shall be released for erection.

47. ERECTION & INSTALLATION

48. ERECTION
 Prior to erection, the interior of all piping components shall be thoroughly cleaned of
loose scale, sand blasting grits or sand and all other foreign matter by air blowing.
 The piping ends shall be covered after inspection to prevent unauthorized removal of
the end cover prior to making the joint to the succeeding section of piping.
 Orifice plates, strainer, rupture discs, Insulation, thermo wells, pressure gauges, in line
instruments, check valves, etc. shall not be installed until the pressure test is
completed.
 Piping shall be installed in such a manner that the resultant force on the equipment
shall be kept to a minimum. Proper care shall be taken at connection joint to pump,
compressor and other mechanical equipment. Flange alignment check shall be
performed and witnessed.
 Piping spools placed in location must be well supported with wooden planks.
 Special care shall be taken to avoid corrosion and damages of machined flange face to
enable proper alignment of connections.
 Field weld joint shall be inspected by Welding Inspector. If the result of inspection is
unacceptable, the joint shall be repaired and re-inspected in accordance with welding
procedure specification. All NDE activities shall be recorded in the Line History Sheet.
 Piping will be disconnected / insulated from rotating equipment until all welding is
complete.
 Special care shall be taken while handling Safety relief valves, control valves, etc.

49. Piping Works on the Pipe Rack
 Straight run pipe shall not be pulled through the pipe racks
unless a roller is used or the steel/precast face is covered with
carpet to avoid paint damage.
 Position of lines shall be marked on the sleeper / pipe rack
beams according to coordinates on Isometrics.
 Spool shall be lifted on the rack / sleepers on their designated
position by using chain pulley block or crane.
 After lifting it shall be inserted into the pipe rack & placed in a
required location, where the welding is going to be carried
out.
 Piping being welded shall be grounded on pipe and not to
steel structure and shall not go through valves or bolted
flanges.
 After placing the pipes, joint fit-up shall be made from
scaffolding platform which is made below the joint location
between two grids.

50.  If tie-in alignment with outside pipe rack piping is
required, coordination of pipe installing between
working teams shall be done for ensuring proper
alignment.
 For installation of slop lines, check levels of tie-in
points (both high and low) shall be checked. The line
slope shall be given between these two points. Slope is
obtained by different shoe height and shim plates.
 For installation of branch, header shall be installed and
aligned before commencement of branch installation.
 During lifting and fit-up by chain block, care shall be
taken to avoid any damage on components of
structure. By distributing load to strong components of
structure, bending or twist of structure shall be
avoided. Structure shall be protected to avoid damage
to the galvanized surface.

51. ERECTION
 Other piping Erection Requirements
The following activities shall be carried out as per approved
Quality Procedure for AG Piping fabrication.
 Cutting and Marking;
 Buttering or Weld Build up on joints;
 Weld Cleaning; Welding
 Tack welds;
 Back purging;
 Seal Welding;
 Weld encroachment and minimum distance between welds;
 Orifice Flange Internal Requirements;
 Welding of Special Corrosion resistance materials (High
Temperature Applications and Corrosive Services)

52. ERECTION
 INSTALLATION OF BRANCH CONNECTION
 For new construction of metallic piping branch connection
selection shall be made in according with chart 1 in SAES-L-
110
 Branch connection such as those for drain and vent connection
on tees, elbows and reducers are not permitted. When not
avoidable piping design shall be approved by company.
 Branch connections with reinforcement pad size pad shall be
as per applicable code.
 Branch connections with reinforcement shall not cover girth
welds.
 Reinforcement pad material shall be of the same pipe material
unless otherwise approved by Company.

53. ERECTION
 PIPING AROUND ROTATING EQUIPMENT (PUMP, COMPRESSOR)
 Pump and compressor piping shall be installed up to a break point
between the nearest pipe support and the equipment.
 No welding will be performed on piping while connected to rotating
equipment.
 Temporary / Permanent support shall be given to the piping all the
time to avoid load on equipment nozzles.
 All bolting will remain loose at rotating equipment until final pipe
stress.
 Final tie-in weld for alignment with equipment nozzle shall be done
after initial alignment of equipment.
 Align equipment nozzle flange and spool flange within acceptable
tolerance by checking gap by dial gauge or filler gauge in minimum
4 points in circle of raised faces. Tie-in weld shall be done during
welding.
 Flange gap shall be checked with filler gauge after welding.
 Final bolt up to rotating equipment will be performed under the
supervision.

54. INSTALLATION
 INSTALLATION OF FLANGE AND STUD BOLT
TIGHTENING
 Prior to flange connection, following points shall be verified to get the good condition of flange
joint.
 Flange faces shall be aligned horizontally and verified.
 Flange faces shall be protected from damage like scratch, dent, rust etc.
 All bolts, nuts and gaskets shall be checked and be free from damage, corrosion and correct size.
 Flange faces shall be cleaned to ensure a good seal. Flange face shall be protected during all stages
of construction, including during installation. End protector for flanges shall be provided.
 Gasket identification for permanent and temporary application shall be as per approved procedure.
 An insulating kit such as PIKOTEC gaskets with isolating bolt sleeves and washers shall be used for
isolating dissimilar metal flanged joints. Insulating gasket not required for the following services.
 -Hydrocarbon gas services.
 -Dry gas services temperature is above the limitation of non-metallic gasket application.
 -When internal liquid media is not an electrolyte.
 -When the mass ration of SS compared to CS is very low where galvanic corrosion in CS is
insignificant.
 Apply lubricants to stud threads over length and nut engagement and to face of nut which contacts
flange. Ensure that the nuts run freely down the thread of the stud. (Refer table SAES-351-01)
 Install all studs and nuts hand tight; ensure that studs pass freely through the flange holes. Position
the nut on one end of the stud such that only the crown of the stud projects beyond the face of the
nut. The excess stud length should project beyond the nut on the other side.
 Number each stud according to its position in the flange as shown in figure.

56. INSTALLATION
 For inserting gaskets enough gap (1/2” of gap is recommended) should be available
between flange faces to avoid any damage to seals during inserting the gaskets, if
due to any reasons, seals are damaged, change the seal before installing gaskets.
 Matting flange faces and the gaskets should be dry free from grease, oil or water.
 Tighten studs per the Stud Bolt Tightening Sequence, for 4 to 32 bolts use Figure
SAES-351-01 and for 36 to 68 bolts see Figure SAES-351-02 for bolts numbering
and then follow the tightening sequence of Table SAES-351-04. An appropriate tool
should be used such as a Torque wrench or equivalent.
 Tighten the stud bolts in stages to obtain the final required torque from the
appropriate torque Table-SAES-351-02. The first stage should not be more the 30%
of the final torque. The final torque shall be within ±5% of the required torque
value.
 The sequence of bolt tightening shall be as follows using the cross technique and
shall be as per approved procedure.
 Align flanges and gasket. Forced tightening is not allowed to overcome non
acceptable alignment tolerances. Clamp securely in place.
 Apply the torque evenly to each stud following the stud bolt tightening sequence.

57. INSTALLATION
FLANGE FIT-UPAND TOLERANCES
 The maximum tolerance for axial dimensions, face-to-face, center-to-face and
location of attachments shall be ± 3mm.
 Lateral transition of branches and connections from the centreline of the run shall
not exceed ± 1.5 mm.
 Flange bolt holes shall be oriented as follows, unless otherwise indicated on the
construction drawings:
• Flange face vertical – bolt holes to straddle vertical centrelines.
• Flange face horizontal – bolt holes to straddle horizontal centrelines.
• Rotation of flanges, measured as the offset between elevations of bolt holes on
opposite sides of a flange centreline, shall not exceed ± 2.4 mm.
• The tilt of a flange measured at the periphery across any diameter shall not
exceed 1.6 mm from the square position.
 For piping over 3-inch NPS and connected to machinery/equipment, flange alignment
shall be within the following limits unless piping analysis per SAES-L-120 shows that
loads and moments are within the manufacture’s limits for the machinery/equipment
nozzle:
• Vertical bolt hole offset: ± 2.4 mm
• Horizontal bolt hole offset: ± 2.4 mm

58. INSTALLATION
• Rotational offset: ± 2.4 mm
• Flange face tilt across diameter : 0.025mm per 25mm (0.001
inch per inch) of flange outside diameter up to a maximum of
0.672 mm (0.030 inch), and 0.254mm (0.010 inch) for all
flanges with an outside diameter less than 10 inches.
• Flange face separation, gasket thickness : ± 1.6 mm
• Combination of vertical, horizontal and rotational offset: ±
3.2 mm
 In the case where a spectacle plate is installed between two flanges,
these tolerances can be increased by 30% except for tolerances for
flanges face tilt across diameter and flange face separation.
 When a piping flange a aligned to a machinery flange, the
machinery alignment should be within the equipment vender
specified tolerances, after the stud bolts of the connecting flanges
are removed following the completion of piping assembly.

59. INSTALLATION
INSTALLATION OF VALVES
 Value shall be installed as shown on the Isometric drawing. The value shall be installed in
accordance with value manual.
 Prior to installation of values, tag number and flow direction will be verify with Isometric
drawing / P&ID and installed accordingly.
 Values will be correctly handled to prevent damage of value body, handle and flange surface.
 Value will be installed in the position as indicated on the isometric drawing.
 Welding between pipe and value will be performed with value open as per manufacture’s
instruction.
 All the internals of Bud Weld / Socket Weld values will be checked before welding and
removed if welding will damage internals (Follow value manufacture’s recommendations for
welding & PWHT)
 Values shall be checked for correct operation before installed and spindle threads will be
preserved to assure good value operation. (No greasing of spindles used in oxygen service).
 Check value in vertical position shall be avoided. In case not avoidable the type of check
value shall be of a kind that it shall not stuck in open position subject to prior approval of
company.
 New values designated for isolation purpose(On-Off) shall be field tested as per approved
procedure.
 The testing includes a high pressure hydrostatic shell test and a high pressure hydrostatic
closure test. Values shall be separated in to inspection lots based on the criteria mentioned
SAES-L-150.

60. INSTALLATION
 INSTALLATION OF PIPING SPECIALITIES AND INSTRUMENTS
 All supports, anchors, guides and other support attachments shall be installed in
accordance with details indicated in the pipe support drawing, isometric drawings
and manufacturer requirements, etc.
 Separate storage facility shall be made to store fabricated supports in area wise and
material wise.
 Fabricated CS, AS, and SS supports shall be placed separately with proper
identification like type of support, sequence No etc. With legible marking.
 Attachments, such as supports Bracing, lugs and T-bars shall be installed in the
field.
 Installation of supports shall be performed in accordance with construction
specification for piping construction works.
 If pipe thickness is very less (below 5 mm), welding activities to be controlled
specially for distortion. The use of U Clamp between pipe & support to be
maximized as allowed by Engineering and project specification.
 A 6mm weep hole shall b drilled for all dummy supports. The weep hole shall be
located near the base plate for all vertical dummy supports and near the run pipe at
6 o’clock for all horizontal supports.
 The spring support shall be in full engagement with pipe. All springs shall be in
compression.
 Rod hangers shall be avoided wherever possible. Rod hangers shall not be used for
lines 12” NPS and larger in liquid or multi phase flow. All hangers shall be
provided with means for vertical adjustments.

61. 5. LINE CHECKING

62.  Check the Pipe rooting as per latest Isometric revision drawing P&ID or Plat Plan.
 Check the Pipe Materials and Fittings are as per Isometric Drawings and
Specification.
 Check the Installed Gasket size , Class, Rating and Color Coding as per Installation
of approved Quality Procedure.
 Check all joints (flange, threaded, welded or mechanical seals) are left exposed for
visual leak detection during the hydrotest.
 Check all permanent flange joints were inspected, gasket mat'l verified & properly
torqued.
 Check the Drains shall be provided at all low points of the piping system.
 Check the vents and drain valves, both temporary and permanent, conforms with
the piping class or rating.
 Check the Arc strikes, gouges, and other indications of careless workmanship (such
as surface porosity, uneven weld profiles, and undercut) shall be removed by
grinding and inspected by magnetic particle or liquid penetrant method.
 Check the Temporary welded attachments to the pipe were ground off and inspected
by magnetic particle or liquid penetrant method.
 Check all threaded joints and faying surfaces shall be seal welded by a continuous
fillet weld (required weep holes shall be left unwelded).
 Check all in line valves that are not used as test isolation valves are in open
position.

63.  Check During filling, permanent vent & drain valves are in open position. Plugging
is only AFTER WATER FILL & EFFICIENT AIR VENTING.
 Disc of check valve is removed, unless check valve has by-pass.
 Check the Spare taps of orifice flanges are plugged and seal welded.
 Check the Process instruments and equipment that may be damaged during
Hydrotest shall be removed.
 Check the Paddle or spectacle blinds shall be used to isolate test sections. Safety of
test "implements" has been checked.
 Check All pressure containing components of pipeline, except instruments that
may be damaged by the test pressure, were physically verified to be included in
test using P&ID, ISOs (Pressure Test Diagram).
 Check the Flange to Flange alignment or Flange alignment to equipment are
acceptable.
 Check the Bolt Specification, Materials, Length, Size and Type used as per Isometric
Drawing.
 Check the correct stud and extends through nut and two to three thread minimum
outside and properly lubricated.
 Check the flow direction of Check Valve / Control valve / Orifice Plate / Stream
Trap and Strainer are as per Isometric Drawing or P&ID.
 Check the Documents of Internal Root Flushing of Orifice Flanges and the
Orientation.
 Check the Tapping or Seal welded .
 Check the Vent and Drain at Correct Location as per Isometric Drawing.
 Check the Piping straightness, Plumbness, Slope and Level as per Isometric
Drawing.
 Check the all Shoe Supports and Trunnion Supports are fully Welded.

64. 6. HYDROTEST

65.  Test Package Documents
 Subcontractor shall provide the marked up P&ID showing the
test limit with corresponding list of lines included in the test.
Subcontractor shall prepare test packages with respect to the
marked up P&ID and list of lines and it shall be submitted to
Contractor/Company for approval of the test packages in
accordance with approved ITP.
 Subcontractor shall indicate on test packages fill point, venting
point, pressure gauge location, temporary spools and
blinds/spectacle plates and Thrust Block location, if applicable.
 The test package shall be formed containing, but not limited to
the following documents.
a) Table of contents
b) Safety Instruction sheet for critical services
c) Flow Chart of Test Packages
d) Pre-Test Punch List
Test Procedure & Pressure Test Diagram
Related P&ID and Isometric Drawings
Line List
Pre·Test PunchList Checklist I Form

66. e) QA/QC Documentation of the system to be tested.
 Weld Inspection Summary Sheet
 Weld Map
 NDE Record/s
 As-Built drawings
 Isolation valve Test Certificates
 Flange Joint Inspection Report
 Internal Cleanliness I Flushing Report
f) Pressure Testing
 Verification of Temporary gaskets
 Verification of Test blind rating
 Checklist for Verification of system readiness for Testing
 Calibration certificates for Pressure gauge & PSV
 Calibration certificates for Pressure & Temperature recorders
 Test manifold Certificate
 Water Analysis (test medium)
 Pressure Test Report Form
 System Lay-Up Certificate
 Re-Instatement or Final Assembly Inspection (Final Punch List)

67. TEST PREPARATION
Equipment Excluded from Pressure Test:
 Following components shall be removed, replaced with temporary piece or
isolated from pipe work, according to the test package.
 Analyzers.
 Flow instruments
 Pressure regulators and switches
 All restrictions to flow such as orifice plates
 Sight glasses & Venturies
 Control valves
 Pressure gauge (Permanent)
 In-Line instruments (If piping have been flushed prior to testing, on/off valve
may be remained in line, but valve shall be kept open during test and flushing.)
 Thermo wells, strainers, filter elements,
 Rotating machinery, such as pumps, turbines and compressors.
 Pressure relieving devices, such as rupture disks and pressure relief valves.
 Locally mounted indicating pressure gauges, where the test pressure will
exceed their scale range.
 Equipment that cannot be drained.

68.  All internal parts and in-line Items removed for the duration of pressure
testing shall be labeled and the component to which they belong or the
position in the line from which they were removed shall also be labeled to
ensure correct replacement of components following the testing.
 ISOLATION OF TEST SECTIONS
 Paddle blinds or spectacle blinds shall be used to isolate the test sections.
They shall be the same class rating of the system or may be fabricated
based on appropriate calculations.
 When a block valve is used for isolating test sections, the differential
pressure across the valve seat shall not exceed the seat test pressure
during pressure testing and shall not exceed the rated seat pressure
during tightness test. Both sides of this valve shall be protected by relief
valves during the test.
 Flanged joints that are broken for pressure test purposes shall have a new
gasket installed after pressure testing is completed prior to
commissioning.
 VENTS AND DRAINS
 Vents shall be provided at all high points in the tested system as needed.
 Excluding scrapable and buried pipelines. Drains shall be provided at all
low points in the system and immediately above check valves in vertical
lines.

69. TEST MEDIUM
 All test water shall be analyzed and the certificates shall be available in the test
package.
 Test the hydrostatic test water entering the system and verify the maximum
allowable chloride concentration is 50 ppm.
 The test medium used for pneumatic test shall be air or inert gas, as indicated in
the isometric diagram.
CLEANING AND FLUSHING
 Spools are visually inspected for internal cleanliness (no presence of loose
particles/flakes or debris) prior to welding/bolting to the preceding and/or
succeeding spools.
 During assembly and erection Construction shall ensure that no foreign materials
(such as welding consumables, lumbers, gloves, etc.) are left inside the piping
system.
 After assembly and installation, the piping shall be cleaned inside to remove all
loose material.
 The interior of the piping for the following specific services shall be cleaned after
hydrostatic pressure testing to remove oil, grease, preservatives and rust.
 Lines to be chemically cleaned shall be identified on the P&ID's and Line Index.
The systems to be cleaned shall have high and low point vents and drains installed.

70. TOOLS AND EQUIPMENTS:
 All equipment, tools and instruments necessary to conduct satisfactory
testing of piping system will be provided.
 Test equipment includes but not limited to the following.
 Mechanized pump unit(s) for hydro testing with suitable test capacity
& rating.
 Manually operated pump(s) for low pressure/low volume test
 Air Compressor & Nitrogen cylinders for pneumatic testing (if required)
 Suitably rated high-pressure test hoses or temporary test piping.
 Test manifolds with permanent calibration tag and certificate.
 Blinds, Plugs (Round head plugs)
 Water Source
 Calibrated pressure gauges & Pressure relief valves with calibration
sticker & Certificate
 Calibrated Thermometers with calibration sticker & Certificate
 Air dryer
 Calibrated Pressure & Temperature Recorders (if required)
 Warning sign barriers.

71. HYDROTEST
 GENERAL REQUIREMENTS.
 All newly constructed plant piping, shall be subjected to a hydrostatic strength
test in accordance with the requirements of SAES-L-150 and ASME B31.3 or
ASME B31.1as applicable.
 New piping systems shall be cleaned in accordance with SAES-L-350.
 Soft seated valves and control valves shall not be installed until alter the lines
have been thoroughly flushed.
 Pressure gauges and pressure recorders shall be calibrated before the tests.
 The calibration interval shall not exceed one (1) month. Calibration
certificates shall be made available to Inspection personnel prior to
commencement of the pressure test. Stickers shall be applied indicating
the latest calibration date.
 All gauges shall have a range such that the test pressure is within 30 to 80%
of the full range.
 A minimum of two pressure gauges are required for the test system. One
pressure gauge shall be on the test manifold and the other(s) on the test
system. Their accuracy shall be within 5% of one another.
 When large systems are tested, Inspection personnel will determine the
need for additional gauges.
 Recording gauges shall be used where it is necessary to keep a permanent
record, e.g., when the test duration exceeds four hours, or otherwise as
required by this standard.

72. HYDROTEST
REQUIREMENTS FOR TEST MANIFOLDS
 Test manifold for new construction shall be revalidated for each new project and every
60 months for operating facilities. (Refer SAES-A-004, 5.5.4.3)
 Test manifold shall have 100% NDE for all Joints.
 An isolation valve shall be provided between the pressure testing manifold and the
system being tested. The isolation valve shall be rated for the manifold test pressure
when in the closed position.
 Before employing the pressure testing manifold in the actual system pressure test, it
shall be separately pressure tested to at least 1.2 times the system test pressure but not
less than the discharge pressure of the pump used for the pressure testing.
 Test fluid shall be filled by using the manifold, temporary piping / Hose at lowest point
of the system and vented of the highest point of the system to minimize the entrapped
air as far as possible. All vent valves shall be opened during filling till system is free from
air, verified by water spouting from the vent.
 The pressure shall be built-up gradually. To ensure the applied pressure inside the test
package never exceeds the desired pressure, a calibrated safety relief valve shall be
provided in the manifold.
 In the event of leakage, the manifold will be depressurized. Repair will be executed and
the test will be repeated until no leakage is observed.
 Each hydrotest manifold shall be uniquely identified by means of either die stamping or
stenciling.

73. HYDROTEST
PROTECTION FROM OVER PRESSURE
 All systems (piping and equipment) while being pressure tested shall be protected from
being over-pressured by the following:
 Relief valve(s) of adequate capacity set to relieve at 5% above the test pressure
shall be installed unless the test pressure is less than 85% SMYS (specified minimum
yield strength) at which time it can be set at 10% above the test pressure. Sizing of
these relief valves used for testing shall follow the requirements of API RP 520, Part
1. The relief valve(s) shall be tested, dated, and tagged within one week prior to the
pressure test for new construction projects, and within one month maintenance
operations.
 In addition to the pressure relieving device, a bleed valve shall be provided to
protect the piping and equipment from overpressure. The bleed valve shall be
readily
 Accessible in case immediate depressurization is required.
 Piping such as drains, vents and piping downstream of pressure relieving devices
that discharge directly to the atmosphere with a maximum internal pressure not
exceeding, 69 kPa (10 psig) can be excluded from in-situ pressure testing.
 All Punch-List "A" Items shall be cleared prior to Pressure Test.
 Safe access any required temporary supports will be provided for inspection of all
joints and appurtenances prior to walk down and maintained until the satisfactory
completion of the test.

74. HYDROTEST
HYDROSTATIC TEST
Filling the Water
Filling and pressurizing shall be done on the
upstream side of check valves in the system. The
test fluid shall be injected at the lowest point in
the system to minimize entrapped air. All vents
shall be opened during filling and closed when
entrapped air has been vented. When filling at
the lowest point is not practical, the Company
inspector shall be consulted.
Filling should be done as explained by the. Flow
Diagram for filling and dewatering for Hydrotest.

75. APPLICATION OF PRESSURE AND INSPECTION
 At 50% of strength test pressure, pressurization shall be stopped to check
for leak.
 If any leakage is found the system shall be depressurized and then
dewatered. For flange bolted joints, stoppage of any dripping can be
achieved by just depressurizing the piping system, without dewatering,
and re-torquing the stud bolts to maximum allowed torque value.
 After satisfactory preliminary check for leaks at 50% of test pressure, the
pressure shall be increased in steps not greater than one-fifth of the
strength test pressure with at least 10 minutes hold at each step to permit
inspection for leakage.
 If no leaks are discovered during these stages, pressurization shall be
continued up to the required test pressure. After the test pressure is
reached and before commencement of Inspection of the system, the
isolation valve between the temporary test manifold/piping and the
piping/equipment under pressure test shall be closed and the test pump
disconnected.
 For lines above-ground, the test pressure shall be maintained for a
sufficient time, but shall not be less than 30 minutes, to determine that
there are no leaks.

76. PNEUMATIC TEST
Pressurization for Pneumatic Strength Test.
 Metal temperature shall be at least 30ºF above minimum design metal
temperature (ASME SEC VIII, Div1, UG-100 c).
 The pressure in the piping system shall be gradually increased until a gauge
pressure which is the lesser of one-half the test pressure or 175 kPa (25 psig) is
attained, at which time a preliminary leak test shall be performed to detect and
eliminate gross leaks and/or weakness in the joints under examination.
 When leakage is observed, the position of the leak(s) shall be marked. The system
will be depressurized gradually and safety released.
 Thereafter, the pressure shall be gradually increased in steps no greater than 1/10
of the strength test pressure, until the required final test pressure is reached. Each
step of pressure rise shall be held for at least 10 minutes to equalize piping strains.
 The strength test pressure is specified by the Hydrostatic Test Diagram and Circuit
List and in accordance with Para. 345.5, of ASME B31.3.
 Strength test pressure holding time shall not be less than 30 minutes as per SAES-
L-150, Para. 7.2.
 Throughout the testing period, the pressure shall be closely monitored to ensure
that over pressurizing due to the thermal expansion does not occur.

77. 7. RE-INSTATEMENT

78. EMPTYING THE SYSTEM
 Depressurization is done slowly and safety after completion of test.
 After completion of the hydrostatic test, vents and drains shall be opened to
remove all the water in the Item. Air may be used to force evacuation. No heat
shall be applied for drying.
 Dewatering shall be done as explained in marked up P&ID for filling and
Dewatering of Hydrotest water.
Reinstatement
 All items removed for the test shall be reinstalled. Items, such as instrument air
tubing, check valve discs which were disconnected before testing shall be re-
connected. The reinstallation of piping component internals shall be carefully
controlled to ensure that they are reinstalled in the correct place.
 Inspect the line/system to ensure that all fittings and appurtenances are returned
to their required position as detailed in the P&ID's.
 Flanged joints opened for those purposes shall be re-made with new gaskets.
 Reinstatement activities shall be performed as per ITP.
 All temporary items installed for testing purpose (e.g. manifold, valves, blinds,
spacers, supports) shall be removed.
 Vent and drain used only for the pressure test shall be plugged & seal welded.
 Isolation valves closed for the test purposes and that are required to be in the
open position for process reasons shall be opened. If the valve cavity has a drain,
the cavity shall be drained. All valves shall be lubricated after the test.

79.  All permanent flange joints were inspected, gasket mat'l verified & properly
torqued.
 Vents and drain valves, both temporary and permanent, conforms with the piping
class or rating.
 Supports are installed. Additional temporary support may be installed as required.
 Expansion joints and spring hangers or spring supports are provided with
temporary restraints.
 Arc strikes, gouges, and other indications of careless workmanship (such as surface
porosity, uneven weld profiles, and undercut) shall be removed by grinding and
inspected by magnetic particle or liquid penetrant method.
 All threaded joints and faying surfaces shall be seal welded by a continuous fillet
weld (required weep holes shall be left unwelded).
 Isolation valves are verified to have been body and seat tested prior to installation
through verification of field test certificates.
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