Sout her n Ar ea Cor r osion Cont r ol
&
I nspect ion Division
I NSPECTOR’S
HANDBOOK
Published:
Fir st Dr af t :
Final Pr oof :
J uly 18, 1999.
Sept ember 8, 1999
Page 2 of 111
Handbook Team:
D. Boult
SAPED/ TSU
Chair per son
A. Br odie
SACCI D
Member
N. Smit h
SACCI D
Member
Gopal
SACCI D
Member
A.K. Al Hamad
SACCI D
Member
A.S. Al Kishi
SACCI D
Member
Compiled by D. Boult ~ SAPED/ TSU (Tel: 576-6147)
Appr oved
______________
A.F. Al Shammar i
Gener al Super visor SACCI D
Page 3 of 111
_________
Dat e
Pr ef ace
This handbook is designed t o give t he f ield I nspect or usef ul
inf or mat ion t o car r y out his wor k saf ely and ef f icient ly. I f
a conf lict ex ist s bet ween t his handbook and any Nat ional
code or Saudi Ar amco st andar d, t hen t he SAES or SAEP
must be deemed cor r ect .
The inf or mat ion cont ained was t aken f r om var ious sour ces
and publicat ion and is as accur at e as possible. I t is t he
r esponsibilit y of t he User t o check any inf or mat ion used f or
of f icial pur poses.
Any inaccur acies or discr epancies should be r epor t ed t o t he
Unit Super visor as soon as possible.
I f t her e ar e any omissions or ar eas not cover ed give t he
det ails t o t he Unit Super visor f or inclusion in t he next
r evision.
The Handbook Team.
Page 4 of 111
Table of Cont ent s
1.0
Paint s & Coat ings
2.0
I nspect ion Repor t s
3.0
Hydr ost at ic Test ing
4.0
W elding Pr ocedur es
5.0
I nspect ion Tools
6.0
Saf et y Guidelines
7.0
Piping
8.0
Conver sion Fact or s
9.0
I nspect ion Ter minology
10.0
Vessels
11.0
Fit t ings
12.0
Codes & St andar ds
13.0
Suppor t s
14.0
Non Dest r uct ive Examinat ion
Page 5 of 111
PAINTS & COATINGS
1.0
Paint s & Coat ings
I nspect ion Met hods And Accept ance Cr it er ia
8.1
Gener al
This sect ion gives t he mandat or y inspect ion met hods and accept ance cr it er ia
t hat shall be met bef or e t he FBE-coat ed welds can be put int o ser vice.
8.2
Visual I nspect ion
The I nspect or shall ver if y t hat t he sur f ace pr epar at ion
r equir ement s of par agr aph 7.2 ar e met pr ior t o t he commencement
of pr eheat ing.
8.2.2
Thickness checks shall be made on each coat ed weld j oint using an
appr oved, cor r ect ly calibr at ed magnet ic dr y f ilm t hickness gauge
(e.g. Micr ot est , Elcomet er or equivalent ). The inst r ument shall be
calibr at ed in accor dance wit h SSPC PA-2.
A minimum number of 6 r eadings shall be t aken on each f ield j oint coat ing t o
ver if y compliance wit h t he t hickness r equir ement in par agr aph 7.3.5.1. The
r eadings shall include t he weld seam.
8.2.3
On t he f ir st 5 j oint s of t he j ob and t wice each day t her eaf t er , t he
qualit y of cur e shall be checked by maint aining a MEK soaked pad in
cont act wit h t he coat ing sur f ace f or one minut e and t hen r ubbing
vigor ously f or 15 seconds. Ther e shall be no sof t ening of t he
coat ing or subst ant ial color r emoval f r om t he coat ing.
8.2.4
The f inished coat ing shall have a unif or m, glossy appear ance and be
f r ee of def ect s such as holidays, f ish eyes, lumps, dr y spr ay, sags
and r uns.
100% of t he coat ed gir t h weld sur f ace ar ea shall be holiday
det ect ed, inspect ed, and r epair ed in accor dance wit h t he
pr ocedur es and equipment specif ied in SAES-H-200 f or t he millapplied FBE coat ing on t he pipe. Holiday det ect ion shall not be
Page 6 of 111
conduct ed if t he sur f ace t emper at ur e of t he coat ed gir t h weld
ar ea exceeds 88 oC.
Pat ch Coat ing
The mat er ial f or pat ch coat ing shall be supplied or appr oved by t he
manuf act ur er of t he powder epoxy coat ing. The pat ch coat ing
shall not be applied when t he pipe sur f ace t emper at ur e is less t han
3 deg C above t he dew point .
6.3
Repair s
6.3.1
Damaged FBE coat ing shall be r epair ed as f ollows:
6.3.1.1
Ar eas smaller t han 1450 sq mm - use t her mal melt st icks or an
epoxy-pat ching compound appr oved by t he RSA.
6.3.1.2
Ar eas lar ger t han 1450 sq mm and smaller t han 0.2 sq m - use an
epoxy-pat ching compound appr oved by t he RSA.
6.3.1.3
Ar eas lar ger t han 0.2 sq m - use APCS-113.
6.3.1.4
The r epair coat ing shall over lap t he adj acent sound coat ing by at
least 13 mm. Coat ing applicat ion shall be accor ding t o t he
Manuf act ur er ' s r ecommendat ions.
6.3.2
Damaged PE coat ing shall be r epair ed as f ollows:
6.3.2.1
I solat ed holidays less t han 150 mm in any dir ect ion - Use a heat
shr ink pat ch appr oved by t he RSA. An aver age of no mor e t han 1
f ield pat ch per 12 met er j oint shall be accept able f or any
consecut ive 100 met er s. Damage in excess of t his shall be sleeved
in accor dance wit h par agr aph 6.3.2.2 or cut out in accor dance wit h
par agr aph 6.3.2.3. The pat ches shall over lap t he adj acent , sound
coat ing by at least 50 mm.
6.3.2.2
Holidays lar ger t han 150 mm in any dir ect ion (including close
spaced, individual holidays t hat cannot be cover ed by a single pat ch
Page 7 of 111
per par agr aph 6.3.2.1) - Use a f ull encir clement heat shr ink sleeve
appr oved by t he RSA. The sleeve shall over lap t he adj acent sound
coat ing by at least 50 mm. Wher e mor e t han one sleeve is
r equir ed, t he sleeves shall be over lapped by at least 50%. A t ot al
of no mor e t han 3 met er s shall be sleeved in t he f ield in any
consecut ive 100 met er s in mount ain t er r ain or 1000 met er s in
ot her t er r ain.
5.2.5
I nt er nal coat ings in dead-leg ar eas shall be holiday f r ee.
5.3
I nt er nal Coat ings, Var ious Ser vices
Cat egor ies
Appr ' d Coat ings Syst
New
Maint .
Const r .
Ar ea t o be Coat ed/
Ot her Remar ks
5.3.1 Wat er
Pot able
APCS-103
APCS-100
APCS-101
APCS-102
APCS-2B
APCS-103
APCS-102
APCS-2B
APCS-100, 101, & 102
must be cer t if ied suit able
f or pot able wat er ser vices.
5.3.2. Wat er Oil
or Gas
APCS-100
APCS-101
APCS-102
APCS-103
APCS-103
APCS-2A
For APCS-2A t he allowable
pH r ange is 5.0 t o 12.0,
t he maximum allowable
ser vice pr essur e is 3445
KPa (ga) (500 psig), and
t he maximum allowable
par t ial pr essur es of H (2)
S and CO (2) ar e each 345
KPa (abs) (50 psia).
Page 8 of 111
5.4
Ext er nal Pipe Coat ings, Cr oss-Count r y
Cat egor ies
Appr ' d Coat ings Syst
New Const r .
Maint .
5.4.1 Bur ied
(Pipe Body)
APCS-104
APCS-105
APCS-106
APCS-109
APCS-113
Ar ea t o be Coat ed/
Ot her Remar ks
APCS-106 may only be
used in cases wher e
subsequent f ield bending
will not be r equir ed, e.g.,
cement -lined pipe.
APCS-113 may be used on
new const r uct ion t o r epair
damaged FBE, t o coat
alr eady cement -lined pipe,
and on shor t r uns of pipe
(60 met er s or less) t hat
will not r equir e subsequent
bending.
5. 4. 2 Bur ied
(Field Gir t h
Welds)
APCS-104
APCS-110
APCS-111
APCS-112
APCS-113
APCS-107
APCS-109
APCS-22
Use APCS-22
if
t he
sur f ace is slight ly damp or
has oil/ salt cont aminat ion.
APCS-113 may be used on
new const r uct ion f or t ie-in
welds and f or gir t h welds
on t hr ust -bor ed pipe.
5. 4. 3 Bur ied
Fit t ings,
Appur t enances,
And Spool Pieces
APCS-104
APCS-113
APCS-19B
APCS-113
APCS-19B
APCS-22
APCS-10
APCS-23
Use APCS-22
if
t he
sur f ace is slight ly damp or
has oil/ salt cont aminat ion.
Tapewr ap (APCS-107 or
APCS-109) is accept able
f or
maint enance
on
t apewr apped or P2-coat ed
lines.
Page 9 of 111
5. 4. 4 Bur ied
Road Cr ossings
APCS-104
APCS-105
APCS-113
APCS-19B
APCS-113
APCS-19B
APCS-107
APCS-109
5. 4. 5 Above
Gr ound
Not
Requir ed
Not
Requir ed
5. 4. 6 Bur ied
Anchor s
See
Comment s
See
Comment s
On sleeved cr ossings, t he
car r ier
pipe shall be
coat ed wit h APCS-104,
APCS-105, APCS-19B, or
APCS-113. The casing shall
be ext er nally coat ed wit h
any of t hese syst ems or
wit h APCS-3.
Coat concr et e anchor s in
accor dance wit h st andar d
dr awing
L-AA-036531.
St eel anchor s shall be
coat ed wit h APCS-113,
APCS-22, or APCS-19B.
5.6 Ext er nal Pipe Coat ings, I n-Plant
Cat egor ies
5. 6. 1 Bur ied (All
ser vices except
insulat ed)
Appr ' d Coat ings Syst
New Const r .
Maint .
See
Remar ks
See
Remar ks
Page 10 of 111
Ar ea t o be Coat ed/
Ot her Remar ks
Same as f or cr oss-count r y
pipe.
Except ions:
APCS-107 and APCS-109
shall not be used on bur ied
hydr ocar bon lines on plot .
5. 6. 2 I nsulat ed
(Cold Syst em)
5. 6. 3 I nsulat ed
(Hot Syst em)
APCS-104
APCS-2A
APCS-10
APCS-105
APCS-108
See
Remar ks
5. 6. 4 Mild
At mospher ic
Exposur e
APCS-4
APCS-6
APCS-26B
5. 6. 5 I ndust r ial
and/ or High
Humidit y
At mospher ic
Exposur e
APCS-1A
APCS-1B
APCS-22
APCS-26B
Same as
new
Const r uct i
on
Applies t o pipe t hat will be
oper at ed cont inuously or
int er miient ly
below
at mopher ic
dew
point .
Cover wit h polyur et hane or
f oam glass insulat ion. For
APCS-2A, cont act RSA if
applied ont o cold sur f aces.
Use APCS17A or APCS-17B
f or t emper at ur es less t han
minus 40 0 C.
See
Remar ks
No coat ing needed wher e
cont inuous
oper at ing
t emper at iur es exceed 65
0
C and t he f acilit y is in
ser vice at least 90% of
t he t ime.
Ot her wise,
obt ain
coat ing
r equir ement s
f r om
r esponsible
Technical
Or gaanizat ion.
APCS-26A
APCS-26B
APCS-1B
APCS-1C
APCS-22
Page 11 of 111
5. 2
Mat erials
5.2.1
Abr asive shall be kept dr y and clean. Regar dless of t he t ype of
abr asive, t he sulphat e, chlor ide, and calcium car bonat e cont ent (if
any) shall not exceed t he levels given in Appendix I of t his
st andar d.
5.2.2
The use of r eclaimed slag abr asives is pr ohibit ed. The use of
r eclaimed gar net is per mit t ed pr ovided it meet s t he r equir ement s
of par a, 5.2.1 and an appr oved r ecycling syst em is ut ilized.
5.2.3
The use of sand as a blast ing abr asive shall be per mit t ed only as
f ollows:
5.2.3.1
The sand shall meet t he r equir ement s given in Appendix I of t his
st andar d.
5.2.3.2
New const r uct ion, ext er ior sur f aces.
Sand meet ing t he
r equir ement s of par a. 5.2.3.1 shall be per mit t ed f or APCS-4,
APCS-6 and APCS-26. I t is also per mit t ed as a pr e-blast ing
medium f or ext er ior sur f aces t o be subsequent ly r e-blast ed wit h
abr asive gr it .
5.2.3.3
Spot r epair s (Maint enance and New Const r uct ion) ext er ior
sur f aces: Sand-meet ing r equir ement s of par a. 5.2.3.1 shall be
per mit t ed f or maint enance/ r epair s t o isolat ed ar eas not
exceeding 0.1 sq. met er s and no mor e t han 5% of t he t ot al ar ea of
t he st r uct ur e is involved.
5.2.3.4
Sand shall not be used as a blast ing abr asive f or immer sion
coat ings.
Except ion: spot r emoval of exist ing coat ings f or
inspect ion pur pose. The af f ect ed ar eas shall be r e-blast ed wit h
abr asive gr it pr ior t o r ecoat ing.
Page 12 of 111
Appendix I - Q ualif icat ion Pr ocedur e For Sand For Abr asive Blast ing
Pr ior t o use, t he Responsible Technical Or ganizat ion shall cer t if y in wr it ing t hat t he
sand meet s t he r equir ement s below:
1.
2.
Physical char act er ist ics: The sand shall be clean, dr y, and f r ee of
cont aminant s.
Composit ion: t he sand shall cont ain mor e t han 90% by weight silicon diox ide
and less t han 2.3% by weight calcium car bonat e.
3.
Loss on ignit ion in accor dance wit h ASTM C146: at 1000 deg C t he sand shall
not lose mor e t han 1% by weight .
4.
Wat er solubles (1:1 ex t r act ): The abr asive shall be less t han 250 ppm
sulf at es and less t han 250 ppm chlor ides, in accor dance wit h ASTM D516
Met hod B and D512 Met hod A r espect ively.
5.
Pr of ile: The anchor pat t er n cr eat ed on mild st eel plat e at 620 kPa (90psi)
nozzle pr essur e dur ing abr asive f low must be in accor dance wit h t he
specif ied r equir ement s of t he applicable APCS Dat a Sheet .
6.
Appear ance: No discer nable cont aminant s shall r emain on t he st eel subst r at e
when viewed t hr ough a5X Dat a Sheet .
A separ at e, new cer t if icat ion is r equir ed f or each j ob. The I nspect or may
r equir e addit ional checks dur ing t he cour se of t he j ob if , in his opinion,
condit ions war r ant it .
Table I I - Calculat ing Df t , Wf t , And Theor et ical Cover age
Dr y Film Thickness (DFT)
No solvent added:
DFT
= WFT
x
% Solids by Volume
Solvent added
DFT
= WFT
x
% Solids by volume
1+ % t hinner by volume
Theor et ical Cover age
Cover age (sq. m)
=
No. L
X % Solids per L
x
Cover age (sq. f t )
=
No. Gal coat ing
X % Solids per L
x
Page 13 of 111
1000
DFT (micr omet er s)
1604
DFT (mils)
Table I – Dew Point Calculat ion Chart Ambient Air Temperat ure
(Degrees Celsius)
43
38
32
27
21
16
10
4
-1
Relat ive
-7
0
0
0
0
0
0
0
0
0
0
C
C
C
C
C
C
C
C
C
C
Humidit y
90
-8
-2
3
8
14
19
25
31
36
42
85
-8
-3
2
7
13
18
24
29
35
40
80
-9
-4
1
7
12
17
23
28
34
39
75
-9
-4
1
6
11
17
22
27
33
38
70
-11
-6
-1
4
10
16
20
26
31
36
65
-11
-7
-2
3
8
14
29
24
29
34
60
-12
-7
-3
2
7
13
18
23
28
33
55
-13
-8
-4
1
6
12
16
21
27
32
50
-14
-9
-5
-1
4
10
15
19
25
30
45
-16
-11
-6
-2
3
8
13
18
23
28
40
-17
-12
-8
-3
2
7
11
16
21
26
38
-19
-13
-9
-5
-1
4
9
14
18
23
30
-21 -16
-11
-7
-2
2
7
11
16
21
Example: if t he air t emper at ur e is 21 deg. C t he r elat ive humidit y is 70%,
t he dew point is 16 deg. C.
Page 14 of 111
49
0
C
47
45
43
42
41
39
38
37
34
33
31
28
25
Sigma Phenguar d Over coat ing Times (Maximum I nt er val)
30
25
Time in Days
20
15
10
5
0
0
10
15
20
25
30
35
Temper at ur e in Degr ees C
Page 15 of 111
40
45
50
Sigma Phenguar d Over coat ing Times (Minimum I nt er val)
16
14
12
Time in Hour s
10
8
6
4
2
0
0
10
15
20
25
30
35
Temper at ur e in Degr ees C
Page 16 of 111
40
45
50
Sigma Phenguar d Over coat ing Times (Time t o I mmer sion)
16
14
12
Time in Days
10
8
6
4
2
0
0
10
15
20
25
30
35
Temper at ur e in Degr ees C
Page 17 of 111
40
45
50
Sigma Phenguar d Times (Pot Lif e)
7
6
Time in Hour s
5
4
3
2
1
0
0
10
15
20
25
Temper at ur e in Degr ees C
Page 18 of 111
30
35
Sigma Phenguar d I nduct ion Time
25
Time in Hour s
20
15
10
5
0
0
10
15
20
Temper at ur e in Degr ees C
Page 19 of 111
25
30
SACCID Inspection
Reports
http://saoo.aramco.com.sa/data/saccid/saccid%20forms/GenlInsp/
SACPID-INSPECTION
INSP-9000
Ultrasonic Thickness Measurements
for Hot Tap/Sleeve Calculations
Plant Number:
Date:
Plant Name:
Equip./Line Number:
System:
Description:
Ref: SAES-L-052, SAEP-311, Standard Drawing L-AB-036719
Equip./Pipe
Details:
Diameter
Grade
Schedule
Flange Rating
Header
Branch per
Dwg.
Continuous Scanning
Measurement of Header in mm
Min Max
1
Branch Centre -Point A.
D
2
Branch Diameter Circle B.
3
Reinforcing Pad Diameter Circle C.
E
C
A
B
4
Reinforcing Sleeve Ends -Line D-D
5
Reinforcing Sleeve Ends -Line E-E
6
180 degree from Point A.
D
E
Flow
Measurement on Header
MIN:
mm
MAX:
mm
Measurement on Sticker
MIN:
mm
MAX:
mm
Signed:
Inspector
Inspection Unit:
Note: For
Sleeve
connection
reinforcement
reinforcement
is required
requirements,
when the branch
referdiameter
to ASME
is more
B31.3,than
B31.4,
70%B31.8,
of the header
ASME Section VIII & SA Standard Drawing L-AB-036719.
cc: Inspection File ____________
File: Abq5\Data\INSPFORM/INSP9000.XLS
Page 20 of 111
Revised: 4/2/2002
SACPID-INSPECTION
INSP-9002
REQUEST FOR RADIOGRAPH, IN LIEU OF HYDROTEST
WAVER NUMBER
(TO BE FILLED IN BY INSPECTION):
REFERENCE:
DATE:
PLANT NO:
SYSTEM #:
BI:
JO:
ORIGINATOR'S NAME:
DEPT/DIV:
JUSTIFICATION:
(PLEASE INCLUDE A DESCRIPTION AND/OR SKETCH OF FACILITIES INVOLVED)
SIGNATURES REQUIRED:
Please
(If applicable)
(RETURN APPROVED ORIGINAL WAIVER TO RESPONSIBLE INSPECTION UNIT)
1)
ORIGINATOR:
2)
UNIT SUPV., PLANT ENGG.
3)
OPERATIONS SUPT.:
4)
SUPV., INSP. UNIT:
5)
GEN. SUPV., SACPID:
6)
MANAGER, OPERATIONS:
sign as
numbered
RADIOGRAPHS WILL BE INTERPRETED TO APPLICABLE CODE.
CONDITIONS OF APPROVAL
File: Abq5\Data\Inspfoorm\Insp9002.xls
Revised: 4/2/2002
SACCID
Date prepared:
FACILITY EXCEPTION ITEM LIST
Prepared by:
Revision
1
2
3
4
ARAMCO 6133-
Approved by:
T INSP-9003
PLT.
Item No.
Section:
Item Description
Date
Subject:
Required Covered
for
by
Startup Contract
Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
abq5 on "a1ecc"/data/inspform/6133.xls
jRevised: 11/28/98
SACCID
INSP-9006
LEAK REPAIR REPORT
(Fill in and/or encircle your choice)
Date Leak Reported:
Date Repair Started:
Date Repairs Completed:
System:
Plant Number:
SACPID/____.:
Date:
DATA
Equipment:
From:
To:
Plant Name:
On Plot: Yes / No
Service: * ( Oil / Gas / Water / Sewer / Firewater/
Disposal / Chem. / Air / Seawater
Installation Date:
(Year)
N2 / SO2 / S / SO2 SOL
Material: *
CS / SS / PVC / FRP / GI / CI/RTR
Injection Water / Supply Water )
Nominal Diameter:
(Inches)
Nominal Wall Thickness:
(Inches)
Restrained: Yes / No
INSPECTOR'S REPORT
LEAK INFORMATION
Leak Location:
Leak Position:
Length / Dia.: HOLE " :
RUPTURE " :
CAUSE : * Corrosion / Erosion / Mechanical / Crack
TYPE: * Internal / External
Corrosion Form: * General / Pit / Lake / Bands/ Groove
Data Base Comments:
Buried: Yes / No
Backfill Type:
Sand / Subkah / Marl / Rocky
EXISTING COATING APPEARANCE
Details:
1. * Smooth / Cracked / Damaged
2. * Adherent / Detatched
Coating Type:
APCS -
I.
II.
Repair:
( Wood plug /Steel plug / Sleeve / Replaced / Weld Overlay/Patch )
NOTE:
You may encircle more than one if necessary.
REPAIR DETAILS:
A.
B.
C.
INSPECTOR:
Inspection File:
* Choose One Only.
File: Abq5\Data\Inspform\Insp9006.xls
FIELD SUPERVISOR:
APPR. FOR COMP. INPUT
SIGNED:
Revised: 4/2/2002
SACCID
PRESSURE TEST REPORT
SAUDI ARAMCO 2642
INSP-9008 (Dec 00)
Reference Details:
Plant Name:
Plant No:
Insp. Unit:
SACPID/
Equipment Description:
Location in Service:
Shop Order:
System #:
DWG No:
SACPID Ref:
Verbal Report To:
At:
[Contact Name & Position]
[Date & Time]
Test Details:
Test Procedure in
Accordance with:
Preliminary Tests:
Initial Test
Revalidation
Test Type:
Repairs During Tests:
Test Fluid:
MAOP:
Test Temp:
Relief Valve Tag #:
Test Pressure:
Relief Valve Test Date:
Test Duration:
Relief Valve Set Pressure:
Test Date:
Pressure Gauge Cal Date:
Gauge Range:
[Hydro /Pneu/ Leak
Sketch:
Test Results:
Accept:
Comments:
Inspector:
Badge #:
Date:
C:\Data\Word\INSP-9008_Form_(Template).dot
Reject:
Conditional:
Field Supervisor:
Badge #:
Date:
Repair
Modification
SACCID
INSP-9009
RADIOGRAPHY REQUEST SHEET
Radiography
Corrosion
Scale
PLANT NAME:
PLANT NO.:
[ ] ON PLOT
[ ] OFF PLOT
FILM
INDENT.
AREA:
INSPECTOR:
INTERPRETER:
SYSTEM #:
Date: __/ __/ __
Date: __/ __/ __
SIZE
LINE IDENTIFICATION
* Type: 1. Offset Side Shot
2. Offset Bottom Shot
DIA. x THKS
TYPE*
3. Contact Side Shot
4. Contact Bottom Shot
Page 25 of 111
FINDINGS/REMARKS
File: ________________
SACCID
INSP-9011
Ultrasonic Testing Inspection Report
Date:
Plant Name:
Plant Number:
Equipment Name:
Size / Line # :
System #:
OSI DWG. # :
Nominal Thk. :
mm
U.T. Location :
Retirement Thk. :
mm
U.T Equipment:
Pressure:
U.T. Measurement:
Probe Size:
mm
Frequency:
Mhz
Gain:
db
Range:
Min:
Technicians:
mm Max:
mm
Verified:
mm
Description / Sketch:
Scale
______
Flow
CLOCK
POSITION
12
12
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
LENGTH
Page 26 of 111
SACCID
INSP-9013
FREQUENT INSPECTION FORM
Plant Name
Plant Number
System Number
Frequency
Start Date
End Date
Letter Book#
Job
Weekly
Monthly
6 Monthly
Yearly
Other: Specify
Weekly
Monthly
6 Monthly
Yearly
Other: Specify
Weekly
Monthly
6 Monthly
Yearly
Other: Specify
Remarks
Inspector
Field Supv.
Plant Name
Plant Number
System Number
Frequency
Start Date
End Date
Letter Book#
Job
Remarks
Inspector
Field Supv.
Plant Name
Plant Number
System Number
Frequency
Start Date
End Date
Letter Book#
Job
Remarks
Inspector
Field Supv.
cc: Supervisor
File: D:\DATA\INSPFORM\INSP9013
Revised: Dec. 1995
Page 27 of 111
SACCID
INSP-9014
VESSEL INSPECTION REPORT
Plant Name:
Plant Number:
Date: ____/____/____
VESSEL DATA
Vessel Name:
Vessel Number:
Length/Height:
Diameter:
Total Surface Area:
System #:
Mat'l:
Year Built:
T-Minimum: Shells:
SIS Number:
Heads:
COATING DATA
Existing Type:
Date Applied:
Existing Dry Film Thk:
New Type:
Date Applied:
New Dry Film Thk:
ANODES
Old
Type:
Number:
% Consumed:
Replaced: YES/NO New Type:
Date Installed: ____/____/_____
Date Installed: ____/____/_____
REMARKS:
Recommendations:
Signed:
Date: ____/____/_____
See reverse for vessel drawing
Page 28 of 111
SACCID
Aramco 4719-0
INSP-9030
ARAMCO INSPECTION PROCEDURES
LIQUID PENETRANT EXAMINATION REQUEST & REPORT SHEET
Log No.
B.I. No.
Job. No.
Plant No.
Plant Name
Contractor
Requested by:
Phone
Location/Kilometer Reference
Aramco Rep.
Unit
Technician
Acceptance Criteria
Material Type
Date
Sch/Wall ThicknPenetrant System
A-3 ____
Ultraviolet Light Used
ITEM DRAWING
NO.
NO.
1
2
3
4
5
Measured UV light Intensity
EQUIPMENT NO/DIA/
LINE REFERENCE
DISTRIBUTION:
Penetrant batch
Batch No:
B-3 ____
Date
Approved by (Proj. Insp.)
Date
Penetrant Mfg. Penetrant Part No. Cleaner/Remover Part No.
Developer Part No.
SYSTEM WELD WELDER EXAM RESULTS
NO.
NO.
SYMBOL ACC.
REJ.
Surface Condition
REPAIR LOCATION
AND DEFECT TYPE
COMMENTS
Note 1: Comments include type of work examined.
New?, Repair?, Rework?, Tope of part if
not weld. etc.
Note 2: All blanks are to be listed in. If information in
particular blank is not applicable, write in N/a
Audited by: _________________________________________
Page 29 of 111
SACCID
INSP-9024
COATING SURVEY
PLANT
#
PLANT NAME
SYSTEM #
:
:
:
DATE:
EXISTING COATING
EQUIP. YEAR
#
BUILT
COATING REPAIR
CORROSION
WELD
%
SIZE
DIA
COATING FAILURE
L.
AREA
COATED
ANODES
REPAIRS
YEAR
TYPE
APPLIED
YEAR
%
LOCATION
TYPE
COATED
Page 30 of 111
TYPE
LOCATION
DEPTH
YES/NO
TYPE
#
SACCID
INSP-9027
PIPELINE HYDROTEST DATA FORM
Plant Name:
Plant Number:
Flowline/Trunkline Name:
System Number:
Hydrotest Date:
/
/
Test Pressure:
PSIG
MAOP:
PSIG
Hydrotest Interval
Year
Comments:
Inspector:
Field Supervisor:
Approved (Data Entry):
Page 31 of 111
SACCID
Aramco 4719-8
INSP-9031
ARAMCO INSPECTION PROCEDURES
MAGNETIC PARTICLE EXAMINATION REQUEST & REPORT SHEET
Log No.
B.I. No.
Job. No.
Plant No.
Plant Name
Contractor
Requested by:
Phone
Location/Kilometer Reference
Aramco Rep.
Unit
Technician
Acceptance Criteria
Material Type Approved by (Proj. Insp.)
Date
Sch/Wall Thick. Magnetic Particles, Mfg.
Particle Color Wet Method
Particles Part No.
Date
Date
Particles Batch No.
or Dry?
Particle Size
Power Supply Descrptn. & Mfg. Pwr. Sup. Model No. & Sl. No. Magnettizing Current:
Amps. _____ AC _____
Prod or Probe Method
Prod of Probe Mfg/Model No./Serial No.
DC _____
Demagnetization Performed? Yes ___ No___
Equipment and Method Used:
Surface Condition & Cleaning
ITEM
NO.
DRAWING EQUIPMENT NO/DIA SYSTEM WELD WELDER EXAM RESULTS
NO.
LINE REFERENCE
DISTRIBUTION:
1
2
3
4
5
#
NO.
SYMBOL
ACC
REJ.
REPAIR LOCATION
COMMENTS
AND DEFECT TYPE
Note 1: Comments include type of work examined.
New?, Repair?, Rework?, Type of part if
not weld. etc.
Note 2: All blanks are to be listed in. If information in
particular blank is not applicable, write in N/a
Audited by: _________________________________________
Page 32 of 111
SACCID
INSP-9035
Ultrasonic Testing Inspection Report
Date: _________________________
Plant Name:
______________ Palnt Number:
_________
Plant Name:
______________ Palnt Number:
_________
Equipment Name: _________________________________
Size / Line #: ____________________________________
Pressure: _____________
System #: _______________
OSI DWG. #: ____________
Nominal Thk.: _____________mm
U.T. Location: ____________
Retirement Thk: ____________mm
U.T. Equipment: ___________
U.T. Measurement:
Probe Size: _________mm
Frequency: _________Mhz
Min: _____ mm
Max: _____mm
Gain: _________db
Range: _________mm
Technicians: ________Verified: _______
Equipment Name: _________________________________
Size / Line #: ____________________________________
System #: _______________
Pressure: _____________
OSI DWG. #: ____________
Nominal Thk.: _____________mm
U.T. Location: ____________
Retirement Thk: ____________mm
U.T. Equipment: ___________
U.T. Measurement:
Probe Size: _________mm
Frequency: _________Mhz
Min: _______ mm Max: _______mm
Gain: _________db
Range: _________mm
Technicians: ________Verified: _______
Description / Sketch:
Description / Sketch:
Scale
Scale
FLOW
CLOCK
POSITION
FLOW
12
12
12
12
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
5
6
6
CLOCK
POSITION
5
5
6
6
7
7
7
7
8
8
8
8
9
9
9
9
10
10
10
10
11
11
11
11
12
12
12
12
LENGTH
LENGTH
Equipment Name: _________________________________
Size / Line #: ____________________________________
Pressure: _____________
System #: _______________
OSI DWG. #: ____________
Nominal Thk.: _____________mm
U.T. Location: ____________
Retirement Thk: ____________mm
U.T. Equipment: ___________
U.T. Measurement:
Probe Size: _________mm
Frequency: _________Mhz
Min: _____ mm
Max: _____mm
Gain: _________db
Technicians: ________Verified: _______
Range: _________mm
Equipment Name: _________________________________
Size / Line #: ____________________________________
System #: _______________
Pressure: _____________
OSI DWG. #: ____________
Nominal Thk.: _____________mm
U.T. Location: ____________
Retirement Thk: ____________mm
U.T. Equipment: ___________
U.T. Measurement:
Probe Size: _________mm
Frequency: _________Mhz
Min: _______ mm Max: _______mm
Gain: _________db
Range: _________mm
Technicians: ________Verified: _______
Description / Sketch:
Description / Sketch:
Scale
Scale
FLOW
CLOCK
POSITION
FLOW
12
12
12
12
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
5
6
6
CLOCK
POSITION
5
5
6
6
7
7
7
7
8
8
8
8
9
9
9
9
10
10
10
10
11
11
11
12
12
12
LENGTH
11
12
LENGTH
Page 33 of 111
SACCID
INSP-9036
CHANGE OF REVALIDATION HYDROTEST INTERVAL
Plant Name:
Plant Number:
Pipeline #:
System Number:
Last Hydrotest Date:
Initial Hydrotest: YES
Existing Hydrotest Interval:
years
Date:
Proposed Hydrotest Interval:
NO
years
Date of Next Hydrotest:
Justification Comments:
Originator
Supervisor, INSPECTION UNIT
Supervisor, PLANT ENGINEERING
CONCURRENCE:
SUPT. PRODUCING OPERATIONS DIV.
Page 34 of 111
SACCID
COATING ENVIRONMENT RECORD SHEET
Plant Name:
DATE
Plant Number:
TIME
AMBIENT TEMP. STEEL TEMP.
ºC
ºC
RELATIVE
HUMIDITY
INSP-9038
DEW POINT
ºC
INSPECTOR
NOTES
1) Record the readings every two hours.
2) Coating shall not be applied if steel temperature is less than 10ºC or more than 50ºC.
3) Coating shall not be applied if steel temperature is less than 3ºC above the dew point (refer to Table I of SAES-H
Page 35 of 111
HYDROSTATIC
TESTING
3.0
Hydr ost at ic Test ing
Types of Pressure Test s and Their Purposes
The f ollowing descr ibes var ious t ypes of pr essur e t est s and t heir pur poses.
Each t est can eit her be a hydr ost at ic t est or , if appr oved by t he Chief
I nspect ion Engineer , a pneumat ic t est . As previously not ed, pressure t est s
will normally by hydrost at ic.
St rengt h Test
A St r engt h Test is a pr essur e t est at an int er nal pr essur e t hat is high
enough t o ver if y t he int egr it y of t he piping and/ or equipment f or ser vice at
t he Maximum Allowable Oper at ing Pr essur e (MAOP). Dur ing t his t est , t he
equipment shall not be subj ect t o impact . The t est pr essur e shall be
maint ained f or a dur at ion of not less t han 30 minut es f or piping and 60
minut es f or exchanger s.
A st r engt h t est is applied in t he f ollowing cases:
• Bef or e piping syst em is init ially placed in ser vice.
• Af t er r epair s or alt er at ions have been made t hat af f ect t he st r engt h of
pr essur e cont aining par t s, except as not ed in SAES-A-004/ SAES-L-56.
• At int er vals as specif ied by Equipment I nspect ionSchedules.
Tight ness Test
A Tight ness Test is a pr essur e t est , which is conduct ed at a r educed
pr essur e f r om t he st r engt h t est pr essur e, and is done immediat ely af t er t he
st r engt h t est . A t ight ness t est only applies t o cr oss-count r y pipelines,
boiler s, and pneumat ic t est s. The pr essur e must be maint ained long enough
t o per mit inspect ion of t he ent ir e syst em f or leaks, and f or at least 10
minut es in all cases.
Page 37 of 111
Leak Test
A Leak Test is a pr essur e t est t o demonst r at e t hat t her e ar e no leaks in t he
syst em at t he t est ar e nor mally conduct ed by Oper at ions dur ing st ar t -up or
commissioning of t he f acilit ies, using appr oved plant pr ocedur es, and ar e
out side t he scope of SAES-A-004 .
Syst em Test
A Syst em Test is an in-sit u st r engt h t est which is applied t o a syst em t hat
is compr ised of piping and ot her equipment t hat oper at e at one MAOP, as
limit ed by t he weakest element in t he syst em.
Service Test
A Ser vice Test is a st r engt h t est f or low-pr essur e ut ilit y ser vices t hat is
conduct ed at t he oper at ing pr essur e wit h t he ser vice f luid.
Revalidat ion Test
A Revalidat ion Test is a pr essur e t est , which is meant t o pr ove t he int egr it y
of bur ied cr oss-count r y pipelines. This t est is conduct ed at t he opt ion of ,
and at t he int er vals set by, t he r esponsible oper at ing or ganizat ion.
Saudi Ar amco Engineer ing St andar d SAES-A-004 and t he applicable
indust r y code pr ovide t est pr essur e r equir ement s. The f ollowing sect ions
discuss t est pr essur es f or plant piping and cr oss-count r y pipelines.
The above was t aken f rom t he Saudi Aramco 1998 Engineering
Encyclopedia.
Page 38 of 111
Gauge Calibr at ion
good f or 1 mont h
12
R/ V Calibr at ion good
f or 1 week
9
15
7
6
Gauge r ange 30% t o
80% of t est
pr essur e
14
13
12
12
5
11
8
3
1
4
2
16
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Hand or reciprocating test pump
Union (TYP.)
Gate Valve (TYP.)
Check Valve.
Pressure Gauge with necessary valves and piping to release the pressure in the transition
piping between the valve on the mainline and pressure.
Relief valve by-pass-piping assembly when pressures exceed relief valve setting.
Pressure Relief Valve
Drain installed at 6.00 O’clock position on the mainline and preferably at the lowest point of
the line being tested. A hose should be installed to the drain valve and run clear of any
excavations to an improved dumping area.
Weld Neck, Raised Face, Ring Joint and Blind Flange (TYP.)
Vent with valve and piping assembly located at the high point of the piping network.
Plug Valve in an open position during a typical hydrotest of more than one component.
Spectacle plate illustrating an opening position during a hydrotest.
Weld Neck, Raised Face or Ring Joint companion flanges.
Calibrated pressure gauge and piping assembly for release of pressure following the mainline
liquid dump.
Calibrated pressure gauge liquid filled (Ethylene Glycol, thick liquid alcohol).
Water discharge and suction.
Page 40 of 111
HYRDROSTATIC TEST PRESSURES
FLANGE AND VALVE
BODY RATING
150
300
600
900
1500
2500
FLANGE AND VALVE BODY
TEST PRESSURE
450
1125
2225
3350
5575
9275
Page 41 of 111
VALVE
RATING
150
300
600
900
1500
2500
VALVE SEAT
TEST PRESSURE
315
815
1630
2440
4075
6785
WELDING
PROCEDURES
4.0
W elding Pr ocedur es
SAEP-1101 Ref iner y Pipe
Mat er ial For m
Base Met al Thickness
Pr ocess
Base Mat er ial
Posit ions
Cur r ent
Polar it y
Weld Pr ogr ession
J oint Type
Bevel Angle
Root Face
Root Opening
Root Bead
Fill/ Cap
Diamet er Range
Filler Met al
Root
Fill/ Cap
Plat e or Pipe
Unlimit ed
SMAW
Car bon St eel (P1) & low alloy st eels
(P3, P4, P5, P9, P11)
All
Dir ect (DC)
Rever se (elect r ode +)
Uphill
Single vee
60 o (± 5 o)
1/ 16" (± 1/ 32")
1/ 8" (± 1/ 32")
E6010 (1/ 8", 5/ 32")
E7018 or E8018-C1 (1/ 8", 5/ 32")
2.5" NPS & gr eat er
EXX10/ 11 (A5.1, A5.5)
EXX15/ 16/ 18 (A5.1, A5.5)
SAEP-1102 Cr oss Count r y (Downhill/ St ovepipe Welding)
Mat er ial For m
Plat e or Pipe
Base Met al Thickness
Unlimit ed
Pr ocess
SMAW
Base Mat er ial
Car bon St eel (P1)
Posit ions
All
Cur r ent
Dir ect (DC)
Polar it y
Rever se (elect r ode +)
Weld Pr ogr ession
Downhill
J oint Type
Single vee
Bevel Angle
60 o (± 5 o)
Root Face
Root Opening
Root Bead
Fill/ Cap
Diamet er Range
Filler Met al
Root / Fill/ Cap
1/ 16" (± 1/ 32")
1/ 16" (± 1/ 32")
E6010 or E7010 (1/ 8", 5/ 32")
E6010 or E7010 (1/ 8", 5/ 32")
2.5" NPS & gr eat er
SAEP-1103 St ainless St eel
Mat er ial For m
Base Met al Thickness
Pr ocess
Base Mat er ial
Posit ions
Cur r ent
Polar it y
Weld Pr ogr ession
J oint Type
Bevel Angle
Root Face
Root Opening
Root Bead
SMAW Welding
Plat e or Pipe
Unlimit ed
SMAW
St ainless st eels (P8)
All
Dir ect (DC)
Rever se (elect r ode +)
Uphill
Single vee
60 o (± 5 o)
1/ 16" (± 1/ 32")
1/ 8" (± 1/ 32")
E308, or 308L, E309, E310, E316
E316L (3/ 32", 1/ 8")
E308, or 308L, E309, E310, E316
E316L (3/ 32", 1/ 8") can be used
2.5" NPS & gr eat er
Fill/ Cap
Diamet er Range
Filler Met al:
Root / Fill/ Cap
Exx10/ 11 (A5.1, A5.5)
EXXX-15/ 16 (A5.4 aust enit ic)
SAEP-1104 St ainless St eel SMAW Welding wit h Backing Ring
Mat er ial For m
Plat e or Pipe
Base Met al Thickness
Unlimit ed
Pr ocess
SMAW
Base Mat er ial
St ainless st eels (P8), nickel (P41)
Page 43 of 111
Posit ions
Cur r ent
Polar it y
Weld Pr ogr ession
J oint Type
Bevel Angle
Root Face
Root Opening
Met al Backing
Root / Fill/ Cap
Diamet er Range
Filler Met al (Root / Fill/ Cap):
St ainless St eels
Nickel Alloys
Dissimilar Welds
and Ni-based (P42-47) alloys t o
t hemselves. Dissimilar met al welds
include: Ni-based alloys t o car bon
st eels, low alloy st eels, st ainless
st eels, nickel and Monel alloys;
Monel alloys j oined t o car bon st eels;
nickel j oined t o st ainless st eels; and
st ainless st eels j oined t o car bon
st eels.
All
Dir ect (DC)
Rever se (elect r ode +)
Uphill
Single vee
45 o (± 5 o)
None
1/ 4" (± 1/ 16")
Car bon st eel backing st r ip
E308, 308L, E309, E310, E316 or
E316L (3/ 32", 1/ 8")
2.5" NPS & gr eat er
EXXX-15/ 16 (A5.4)
Ni-based (A5.11)
Ni-based (A5.11)
SAEP-1105 Dissimilar St eels
Mat er ial For m
Plat e or Pipe
Base Met al Thickness
Unlimit ed
Pr ocess
SMAW
Base Mat er ial
Nickel alloys (P4X) t o t hemselves
and t o car bon st eels. Dissimilar
met al welds include: Ni-based alloys
t o car bon st eels, low alloy st eels,
st ainless st eels, nickel and monel
Page 44 of 111
Posit ions
Cur r ent
Polar it y
Weld Pr ogr ession
J oint Type
Bevel Angle
Root Face
Root Opening
Met al Backing
Root / Fill/ Cap
Diamet er Range
Filler Met al
alloys; monel alloys j oined t o car bon
st eels; nickel j oined t o st ainless
st eels; st ainless st eels t o car bon
st eels.
All
Dir ect (DC)
Rever se (elect r ode +)
Uphill
Single vee
60 o (± 5 o)
1/ 16" (± 1/ 32")
1/ 8" (± 1/ 32")
None
EniCr Fe-3 (1/ 8", 5/ 32")
2.5" NPS & gr eat er
Ni-based (A5.11)
SAEP-1106 Aluminum GTAW (TI G Welding)
Mat er ial For m
Plat e or Pipe
Base Met al Thickness
0.474" maximum
Pr ocess
GTAW
Base Mat er ial
Aluminum and aluminum alloys (P21,
P22, P23, and P25) t o each ot her
Posit ions
All
Cur r ent
Alt er nat ing (AC)
Shielding Gas
Ar gon (10-20 CFH)
Gas Backing
Not r equir ed
Tungst en Elect r ode
1/ 8" 1/ 2-1% Zir conium oxide
Weld Pr ogr ession
Uphill
J oint Type
Single vee
Bevel Angle
60 o (± 5 o)
Root Face
None
Root Opening
1/ 4" (± 1/ 16")
Met al Backing
Aluminum backing st r ip
Root / Fill/ Cap
ER4043 (1/ 8")
Page 45 of 111
Diamet er Range
Filler Met al
2.5" NPS & gr eat er
ERXXXX, (5.10)
SAEP-1107 St ainless St eel
Mat er ial For m
Base Met al Thickness
Pr ocess
Base Mat er ial
(TI G Welding)
Plat e or Pipe
0.436" maximum
GTAW
Car bon st eels (P1), low alloy st eels (P3,
P4, P5, P9, & P11), st ainless st eels (P8)
only t o t hemselves. And car bon & low
alloy st eels t o each ot her .
All
Dir ect (DC)
St r aight (elect r ode -)
Ar gon (10-20 CFH)
Ar gon (2-5 CFH)
3/ 32" 2% Thor iat ed
Uphill
Single vee
60 o (± 5 o)
1/ 16" (± 1/ 32")
1/ 8" (± 1/ 32")
None
Posit ions
Cur r ent
Polar it y
Shielding Gas
Gas Backing
Tungst en Elect r ode
Weld Pr ogr ession
J oint Type
Bevel Angle
Root Face
Root Opening
Met al Backing
Root / Fill/ Cap
St ainless st eel
Car bon St eel
Low Alloy St eel
St ainless St eel
Diamet er Range
ER308L (3/ 32") or ER309L ER316L
ERXXS-X (A5.18)
ERXX (X) S-X (X) (A5.28)
ERXXX (A5.9)
1" NPS and gr eat er wit h no r est r ict ions.
For t he occasional j ob r equir ing welding
of but t j oint s less t han (1") diamet er , t he
welder shall weld a 2G and 5G-t est
coupon on t he smallest j ob size diamet er
Page 46 of 111
t ubing. The OI U I nspect or shall wit ness
t he welding and t he weld r adiogr aphed.
SAEP-1108 Small Bor e St ainless St eel (TI G Welding)
Mat er ial For m
Plat e or Pipe
Base Met al Thickness
0.436" maximum
Pr ocess
GTAW
Base Mat er ial
Nickel (P41) and Ni-based alloys (P42-47)
t o t hemselves and t o each ot her .
Dissimilar met al welds include Ni-based
alloys t o car bon st eels, low alloy st eels,
st ainless st eels, nickel monel alloys;
Monel alloys j oined t o car bon st eels;
nickel j oined t o st ainless st eels; and
st ainless st eels t o car bon st eels.
Posit ions
All
Cur r ent
Dir ect (DC)
Shielding Gas
Ar gon (10-20 CFH)
Gas Backing
Ar gon (2-5 CFH)
Tungst en Elect r ode
3/ 32" 2% Thor iat ed
Weld Pr ogr ession
Uphill
J oint Type
Single vee
Bevel Angle
60 o (± 5 o)
Root Face
1/ 16" (± 1/ 32")
Root Opening
1/ 8" (± 1/ 32")
Met al Backing
None
Root / Fill/ Cap
ERNiCr -3 (3/ 32")
Filler Met al
A5.14
Diamet er Range
1" NPS and gr eat er
Page 47 of 111
SAEP-1109 Aluminum (TI G Welding)
Mat er ial For m
Plat e or Pipe
Base Met al Thickness
0.474" maximum
Pr ocess
GTAW
Base Mat er ial
Aluminum and aluminum alloys (P21, P22,
P23, P25) t o each ot her
Posit ions
All
Cur r ent
AC (Alt er nat ing)
Shielding Gas
Ar gon (10-20 CFH)
Gas Backing
Ar gon (2-5 CFH)
Tungst en Elect r ode
1/ 8" 1/ 2-1% Zir conium oxide
Weld Pr ogr ession
Uphill
J oint Type
Single vee
Bevel Angle
60 o (± 5 o)
Root Face
1/ 16" (± 1/ 32")
Root Opening
1/ 8" (± 1/ 32")
Met al Backing
None
Root / Fill/ Cap
ER4043 (1/ 8")
Filler Met al
ERXXXX, (A5.10)
Diamet er Range
2.5" NPS and gr eat er
SAEP-1112 Small Bor e Piping
Mat er ial For m
Pipe
Base Met al Thickness
0.436" maximum
Pr ocess
SMAW
Base Mat er ial
Car bon St eel (P1)
Posit ions
All
Cur r ent
DC
Polar it y
Rever se (elect r ode +)
Weld Pr ogr ession
Uphill
J oint Type
Single vee
Bevel Angle
60 o (± 5 o)
Root Face
1/ 16" (± 1/ 32")
Root Opening
1/ 8" (± 1/ 32")
Met al Backing
None
Root
E6010 (3/ 32" or 1/ 8")
Page 48 of 111
Fill/ Cap
Filler Met al
Root
Fill/ Cap
Diamet er Range
E7018 or E8018-C1 (3/ 32" or 1/ 8")
EXX10/ 11 (A5.1, A5.5))
EXX15/ 16/ 18 (A5.1, A5.5))
1" NPS and gr eat er
SAEP-1114 Plate Welding
Material Form
Plate
Process
SMAW
Base Material
Carbon Steel (P1) and low alloys steels
(P3, P4, P5, P9, P11) to themselves and to
each other
Positions
All
Current
DC
Polarity
Reverse (electrode +)
Weld Progression
Uphill except for the root bead which can
be run uphill or downhill
Root Bead
Uphill or downhill (downhill progression
can only be performed with E6010)
(E7018 Uphill progression only)
Fill/Cap
Uphill
Backside Arc gouged
Uphill
Joint Type
Single vee
Bevel Angle
60o (± 5o)
Root Face
1/8" (± 1/ 16")
Root Opening
1/8" (± 1/ 16")
None
E6010 (3/16") or E7018 (1/8")
E7018 (1/8" or 5/32")
Metal Backing
Root
Fill/Cap
Filler Metal
Root
Fill/Cap
Base Metal Thickness
EXX10/11 (A5.1, A5.5)) or EXX15/16/18
(A5.1, A5.5)
EXX15/16/18 (A5.1, A5.5)
Unlimited
Page 49 of 111
Weld J oint Pr epar at ion
For mula f or Cr oss Sect ion Ar ea
For mula f or Cr oss Sect ion Ar ea
For mula f or Cr oss Sect ion Ar ea
CSA = RO x T
CSA = 1/ 2(S) 2
CSA = 1/ 2(S 1 x S2 )
RO
S
S
1
S
S
T
2
Fillet Weld
(Unequal Legs)
Fillet Weld
(Equal Legs)
Squar e
For mula f or Cr oss Sect ion Ar ea
For mula f or Cr oss Sect ion Ar ea
A
+ RO x T
2
CSA = (T - RF)2 t an A + RO x T
2
CSA = 1/ 2(T - RF)2 t an
A
A
RF
RF
RO
T
Single V
RO
Double V
The Fillet Weld
8
(1) BASE METAL:
Met al t o be welded.
(2) BOND LI NE:
The j unct ion of t he weld
met al and t he base met al.
(3) DEPTH OF FUSI ON:
The dist ance t hat f usion
ext ends int o t he base met al
(4) FACE OF WELD:
The exposed sur f ace of a weld on t he
side f r om which t he weld was done
(5) LEG OF FI LLET WELD:
(6) ROOT OF WELD:
5
4
2
The dist ance f r om t he r oot of t he j oint
t o t he t oe of t he f illet weld.
The point or point s, as shown in
cr osssect ion,
at which t he bot t om of t he weld int er sect s
t he base met al sur f ace or sur f aces.
3
1
(7) THROAT OF FI LLET WELD: The shor t est dist ance f r om t he r oot of
t he f illet weld t o it s f ace.
6
(8) TOE OF A WELD:
The j unct ion bet ween t he f ace of a weld
and t he base met al.
Page 50 of 111
7
ELECTRODES FOR WELDI NG SI MI LAR AND DI SSI MI LAR METALS
Carbon
Steel
Carbon
Steel
Killed
Steel
E6010
E7018
E7018
Carbon
Moly
Steel
E7018
E7010
E7018
Carbon
Moly
Steel
E7010 A1
(for plate)
E7010 A1
(for pipe
only)
Killed
Steel
Cast Iron
Cast Iron
Certanium
889
Ni-Rod 55
Braze
(Oxweld
25M)
Certanium
889
Ni-Rod 55
Braze
(Oxweld
25M)
Certanium
889
Ni-Rod 55
Braze
(Oxweld
25M)
Certanium
889
Ni-Rod 55
Braze
(Oxweld
25M)
Gas Weld
(Cast iron
filler rod)
304 SS
(18-8 Cr.
Ni.)
1. E309
2. Inco A
3. E310*
310 SS
(25-20
Cr.-Ni.)
1. E309
2. Inco A
3. E310*
316 SS
Inconel
Incoloy
1. E309
2. Inco A
3. E310*
Inconel
182
Inco A
1. E309
2. Inco A
3. E310*
1. E309
2. Inco A
3. E310*
1. E309
2. Inco A
3. E310*
Inconel
182
Inco A
1. Hast.
B
2.
Inconel
182
1. E309
2. Inco A
3. E310*
1. E309
2. Inco A
3. E310*
1. E309
2. Inco A
3. E310*
Inconel
182
Inco A
1. Hast.
B
2.
Inconel
182
Braze
(Oxweld
25M)
Braze
(Oxwel
d 25M)
X
1. Hast.
B
2.
Inconel
182
3. E310
1. Hast.
B
2.
Inconel
182
3. E310
1. Hast.
B
2.
Inconel
182
3. E310
Inco A
X
E308
304 SS (188)
Cr. Ni.
310 SS
(25-20 Cr.
Ni.)
X
X
1. E309
2. E308
1. E308
2. E316
Inconel
182
Inco A
E310
1. E309
2. E316
Inconel
182
Inco A
E316
Inconel
182
Inco A
Inconel
182
Inco A
316 SS
Inconel
Incoloy
1. Inco
A
2.
E310*
Hastello
y
B
Page 51 of 111
Hastelloy
B
1. Hast.
B
2.
Inconel
182
Inco A
1. Hast.
B
ELECTRODES FOR WELDING SIMILAR AND DISSIMILAR METALS (Continued)
Hastelloy
C
Monel
Brass
Hast. C 1. Monel Braze
Carbon
190
Steel
1-1/4% &
2-1/4%
3-1/2%
2. Inco A
Nickel
5%
9%
12%
Chrome Moly Chrome Moly Chrome Moly
1. E7018
A 1. E7018
B 1. E7018
B 1. E9018 B3 B 1. Inco A A
(Oxweld 2. Inco A A 2. E9018 B3 B 2. E9018 B3 B 2. E502
25M) 3. E8018 C2 A
3. E502
B 3. Murex
4. E310*
A
Killed
190
Steel
2. Inco A
Braze 1. E7018
A 1. E7018
B 1. E7018
Carbon
190
Moly
2. Inco A
Braze 1. E7018
A 1. E7018
Cast
Braze
(Oxweld (Oxweld
Iron
25H)
1. Hast. C Inconel
304 SS 2. Inconel
(18-8
Braze
25H)
X
182
B
4. E310*
A Croloy 9A B
A
B 1. E9018 B3 B 1. Inco A A
B 2. E310
A
3. E410
B
3. E502
B 3. Murex
4. E310*
A Croloy 9A B
4. E310*
X
A
3. E410
B 3. Murex
(Oxweld 2. Inco A A 2. E9018 B3 B 2. E9018 B3 B 2. E502
Steel
B 2. E310
3. E502
B 1. E7018
25H) 3. E8018 C2 A
B
A
4. E310*
Hast. C 1. Monel
A
3. E410
B 1. E9018 B3 B 1. Inco A A
(Oxweld 2. Inco A A 2. E9018 B3 B 2. E9018 B3 B 2. E502
25H) 3. E8018 C2 A
B 2. E310
Croloy 9A B
4. E310*
Hast. C 1. Monel
Chrome SS
A
Braze
Braze
Braze
Braze
Braze
(Oxweld
(Oxweld
(Oxweld
(Oxweld
(Oxweld
25H)
25H)
25H)
25H)
25H)
1. E309
A 1. E309
A 1. E309
A 1. E309
A 1. Inco A A
2. Inco A A 2. Inco A A 2. Inco A A 2. Inco A A 2. E310
A
182
Cr. Ni.) 3. E310
1. Hast. C Inconel
310 SS 2. Inconel
(25-20
182
X
1. E309
A 1. E309
A 1. E309
A 1. E309
A 1. Inco A A
2. Inco A A 2. Inco A A 2. Inco A A 2. Inco A A 2. E310
182
Cr. Ni.) 3. E310
Page 52 of 111
A
Hastelloy
316 SS
1-1/4% &
2-1/4%
3-1/2%
C
Monel
Brass
1. Hast. C
Inconel
X
2. Inconel
182
Nickel
5%
Chrome Moly Chrome Moly
1. E309
9%
12%
Chrome Moly
Chrome SS
1. E309
A
A 1. E309
A
2. Inco A
A 2. Inco A
A 2. Inco A
A 2. Inco A
1. E309
A
A 2. E310
1. Inco A A
A Inco A
A Inco A
A Inco A
A 1. Inco A A
A
182
3. E310
Inco
A
Inconel
Inconel
182
Braze 1. Inco A
(Oxweld 2. E310
A
2. E310
A
25H)
Inco
A
Incoloy
Inconel
182
Braze 1. Inco A
A Inco A
(Oxweld 2. E310
A Inco A
A Inco A
A 1. Inco A A
A
2. E310
A
25H)
Hast. B
Hastelloy
1. Monel
X
Hast. B
A
190
B
1. Hast. B
A
2. Inco A
A
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2. Inco A
Hast. B
1. Monel
Hastelloy
190
C
2. Inco A
Monel
Monel
190
Brass
X
Hast. B
A
Braze 1. Monel
(Oxweld
1. Hast. B
A
2. Inco A
A
A Inco A
A
190
25H)
2. Inco A
Braze
X
A
(Oxweld
25H)
3-1/2%
1. E8018 C2 B
Nickel
2. Inco A
A
E9018 B3 B 1. E9018 B3 B 1. E9018 B3 B Inco A
1-1/4% &
2. E502
B 2. E502
2-1/4%
3. E310*
B 3. Murex
Chrome Moly
A
B
Croloy 9A B
4. E310*
E502
B 1. E502
5%
B
B Inco A
A
2. Murex
Chrome Moly
Croloy 9A B
3. E310*
B
1. Murex
9%
Inco A
A
Croloy 9A B
2. E310*
B
12%
Chrome SS
1. E410
B
2. Inco A A
3. E310* B
Page 53 of 111
1-1/4% &
3-1/2%
2-1/4%
Monel
Brass
Nickel
Chrome Moly
Monel
Braze 1. Monel
A Inco A
A
Monel
190
(Oxweld
190
25H) 2. Inco A A
Braze
X
X
Brass
(Oxweld
25H)
3-1/2% 1. E8018 C2 B
X
Nickel 2. Inco A A
E9018 B3 B
1-1/4% &
2-1/4%
Chrome Moly
5%
9%
Chrome Moly Chrome Moly
X
X
12%
Chrome SS
X
X
X
X
X
X
X
1. E9018 B3 B 1. E9018 B3 B Inco A A
2. E502
B 2. E502
B
3. E310*
B 3. Murex
Croloy 9A B
4. E310* B
E502
B 1. E502
B Inco A A
5%
2. Murex
Chrome Moly
Croloy 9A B
3. E310* B
1. Murex
Inco A A
9%
Croloy 9A B
2. E310* B
12%
1. E410
B
Chrome SS 2. Inco A A
3. E310* B
Page 54 of 111
Page 55 of 111
Page 56 of 111
INSPECTION TOOLS
5.0
I nspect ion Tools
The f ollowing is a list of some auxiliar y it ems t hat can be used t o assist in
conduct ing an ef f ect ive visual inspect ion.
• St andar d f or ms/ inspect ion checklist
This it em includes t he Saudi Ar amco EI S f or m, if appr opr iat e; as well as any
ot her appr oved pr ocedur al checklist s.
• Not ebook and pencil
Use a not ebook and pencil t o wr it e down obser vat ions at t he t ime t hey ar e
made r at her t han at t empt ing t o r ecall t hem lat er .
• Or iginal designs and dat a f r om ear lier inspect ions
Ref er t o new or pr eviously not ed condit ions in or der t o dist inguish bet ween
deviat ions and nor mal or desir ed condit ions. Not es and phot ogr aphs or
dr awings f r om ear lier inspect ions can be usef ul in making decisions about
cur r ent condit ions.
• Cleaning t ools
When needed, use simple cleaning t ools such as a scr aper or st eel br ush t o
clean a sur f ace bef or e making a pr eliminar y visual inspect ion. Chalk or similar
mar king device. Use mar king mat er ials such as chalk t o ident if y pot ent ial or
suspect ed pr oblem ar eas.
• St r aight r uler , squar e, and level
Use t hese it ems t o measur e pr oblem ar eas and r ecor d t he r esult s f or use in
f ollow-up inspect ions or t r eat ment s.
• Vernier , micromet er , and measur ing t ape
Use t hese simple measur ing t ools t o det er mine and r ecor d mat er ial
t hicknesses, a key indicat or of cor r osion.
Visual inspect ions can include bot h ext er nal and int er nal sur f aces of
equipment . I nt er nal sur f aces, especially, ar e of t en inaccessible and r equir e
t he use of special inspect ion t ools. I n addit ion t o t he auxiliar y it ems list ed
ear lier , t he f ollowing t ools can be used t o gat her and r ecor d dat a dur ing
visual inspect ions.
Page 57 of 111
• Fiber Opt ics
• Pit Gauges
• Camer as
• Mir r or s
• Magnet s
The uses, advant ages, and limit at ions of each of t hese inst r ument s will be
discussed in dept h lat er in t his module.
Visual Det ails of Cor r osion Types
Pit Gauges
Descript ion/ Operat ion. Pit gauges ar e inst r ument s used t o measur e t he
dept h of pit t ing by placing a calibr at ed r od in t he pit .
Applicat ion. Pit gauges ar e used t o access t he sever it y of localized
cor r osion pit t ing. They can be used t o measur e t he dept h and widt h of a
depr ession or cavit y in a pit t ed met al sur f ace. The dist r ibut ion of t he at t ack
and an indicat ion of t he r at e of cor r osion can be det er mined by using t hese
t ools.
Page 58 of 111
Advant ages and Limit at ions. Pit gauges ar e r elat ively simple t o use and t he
dat a gat her ed by using t hem is easily int er pr et ed. These t ools can be used
t o measur e t he dept h of pit t ing on any accessible sur f ace.
Mirrors
Descript ion/ Operat ion. To handle a var iet y of cir cumst ances, mir r or s of
var ying sizes should be available, f r om a small dent ist -st yle mir r or f or small
openings t oo much lar ger mir r or s f or lar ger ext er ior sur f aces. Miniat ur e
light sour ces can be at t ached t o mir r or s in or der t o illuminat e dar k ar eas.
Applicat ion. Mir r or s can be used t o obser ve inaccessible ar eas such as t he
ext er nal sur f aces of pipelines t hat ar e near t he gr ound or a wall. They can
also be used t o inspect t he under side of a pipe t hat is dif f icult t o see.
I n addit ion, mir r or s can be used t o look ar ound cor ner s or t hr ough small
openings.
Advant ages and Limit at ions. The advant ages of mir r or s include t he f act
t hat t hey ar e simple t o “oper at e” and easy t o use. They ar e also inexpensive.
Their gr eat est limit at ion is t he f act t hat , alt hough mir r or s ar e an ef f ect ive
t ool f or close-up obser vat ion, t heir usef ulness is limit ed t o shor t -r ange
viewing.
Magnet s
Applicat ion. Magnet s can assist in ident if ying t he individual mat er ial
composit ion of a piece of equipment by checking t he magnet ic pr oper t ies.
Since only a f ew met als ar e easily ident if ied by visual obser vat ion alone, a
magnet can be used t o dist inguish, f or example, bet ween magnet ic t ypes of
st eel and nonmagnet ic st ainless st eel and ot her alloys.
Advant ages and Limit at ions. Magnet s pr ovide a simple, easy, and
inexpensive means of ident if ying cer t ain t ypes of met al. This simplicit y is
also a limit at ion since t he use of magnet s as an inspect ion t ool is limit ed t o
t his single applicat ion.
Page 59 of 111
6.0
Saf et y Guidelines
Basic Saf et y Pr ecaut ions
Bur n Pr ot ect ion
Molt en met al spar ks, molt en slag, and welding, cut t ing and ot her
r elat ed pr ocesses pr oduce hot met al sur f aces. Ser ious bur ns can
occur if cor r ect pr ecaut ionar y measur es ar e not t aken.
Appr opr iat e f oot wear , clot hing and eye pr ot ect ion should be used.
Fumes & Gases
Many welding, cut t ing and r elat ed pr ocesses pr oduce f umes and
gases, which may be har mf ul t o healt h. Avoid br eat hing ar cwelding f umes at all t imes. When inspect ing welding in a conf ined
ar ea, ensur e t her e is an adequat e vent ilat ion syst em.
Radiat ion Bur ns
Ar c welding pr oduces ult r a-violet and inf r ar ed r adiat ion r ays,
which will sever ely bur n exposed eyes and skin. Always wear
pr ot ect ive clot hing and eye pr ot ect ion t o pr ot ect t he skin and eyes
f r om r adiat ion bur ns.
Elect r ical Hazar ds
Elect r ic shock can kill. However , it can be avoided if t he cor r ect
saf et y pr ecaut ions ar e pr act iced. Never t ouch live elect r ical
par t s. The manuf act ur er ' s inst r uct ions and r ecommended saf e
pr act ices should be r ead and under st ood. Fault y inst allat ion,
impr oper gr ounding and incor r ect oper at ion and maint enance of
elect r ical equipment ar e all sour ces of danger .
Page 60 of 111
PIPING
7.0
Nominal
Pipe
Size
1
Piping
ANSI B36. 10W elded and Seamless W rought Pipe
Out
Side
Sched
Sched
Sched
St and
Sched
Diam.
10
20
30
ar d
40
1.315
-
-
-
0.133
0.133
Sched
60
-
2
2.375
-
-
-
0.154
0.154
-
2½
2.875
-
-
-
0.203
0.203
-
3
3.5
-
-
-
0.216
0.216
-
3½
4.0
-
-
-
0.226
0.226
-
4
4.5
-
-
-
0.237
0.237
-
5
5.563
-
-
-
0.258
0.258
-
6
6.625
-
-
-
0.280
0.280
-
8
8.625
-
0.250
0.277
0.322
0.322
0.406
10
10.75
-
0.250
0.307
0.375
0.365
0.500
12
12.75
-
0.250
0.330
0.375
0.406
0.562
14
14.0
0.250
0.312
0.375
0.375
0.438
0.594
16
16.0
0.250
0.312
0.375
0.375
0.500
0.656
18
18.0
0.250
0.312
0.438
0.375
0.562
0.750
20
20.0
0.250
0.375
0.500
0.375
0.594
0.812
22
22.0
0.250
0.375
0.562
0.375
-
0.875
24
24.0
0.250
0.375
-
0.375
0.688
0.969
26
26.0
0.312
0.500
0.625
0.375
-
-
28
28.0
0.312
0.500
0.625
0.375
-
-
30
30.0
0.312
0.500
0.625
0.375
-
-
32
32.0
0.312
0.500
0.625
0.375
0.688
-
34
34.0
0.312
0.500
0.625
0.375
0.688
-
36
36.0
0.312
0.500
0.625
0.375
0.750
-
38
38.0
-
-
-
0.375
-
-
40
40.0
-
-
-
0.375
-
-
Page 61 of 111
Nominal
Pipe
Size
ANSI B36. 10W elded and seamless W rought Pipe
Out
Side
Ext r a
Sched
Sched
Sched
Sched
Diam.
St r ong
80
100
120
160
XX
St r ong
0.358
1
1.315
0.179
0.179
-
-
0.250
2
2.375
0.218
0.218
-
-
-
0.436
2½
2.875
0.276
0.276
-
-
0.375
0.552
3
3.5
0.300
0.300
-
-
0.438
0.600
3½
4.0
0.318
0.318
-
-
-
-
4
4.5
0.337
0.337
-
0.438
0.531
0.674
5
5.563
0.375
0.375
-
0.500
0.625
0.750
6
6.625
0.432
0.432
-
0.562
0.719
0.864
8
8.625
0.500
0.500
0.594
0.719
0.906
0.875
10
10.75
0.500
0.594
0.719
0.844
1.125
1.000
12
12.75
0.500
0.688
0.844
1.000
1.312
1.000
14
14.0
0.500
0.750
0.938
1.094
1.406
-
16
16.0
0.500
0.844
1.031
1.219
1.594
-
18
18.0
0.500
0.938
1.156
1.375
1.781
20
20.0
0.500
1.031
1.281
1.500
1.969
-
22
22.0
0.500
1.125
1.375
1.625
2.125
-
24
24.0
0.500
1.219
1.531
1.812
2.344
-
26
26.0
0.500
-
-
-
-
-
28
28.0
0.500
-
-
-
-
-
30
30.0
0.500
-
-
-
-
-
32
32.0
0.500
-
-
-
-
-
34
34.0
0.500
-
-
-
-
-
36
36.0
0.500
-
-
-
-
-
38
38.0
0.500
-
-
-
-
-
40
40.0
0.500
-
-
-
-
-
Page 62 of 111
Plant Piping
• Unless limit ed by f langes or by valves in t he line, t he hydr ost at ic st r engt ht est pr essur e shall be calculat ed t o pr oduce a hoop st r ess of 90% of t he
specif ied minimum yield st r engt h (SMYS), but shall not be less t han t he
minimum t est pr essur e t hat is det er mined per ASME/ ANSI B31.3. For new
inst allat ions, t he t est pr essur e shall be calculat ed based on nominal pipe wall
t hickness less mill t oler ance (manuf act ur er ' s minus t oler ance). St r engt h
t est pr essur es f or exist ing piping shall be per ASME/ ANSI B31.3, based on
t he design pr essur e.
• Based on ASME/ ANSI B31.3, Par agr aph 345.4, f or hydr ost at ic leak t est s,
t he hydr ost at ic t est pr essur e at any point in a met allic piping syst em shall
be as f ollows:
(a) Not less t han 1-1/ 2 t imes t he design pr essur e.
(b) For design t emper at ur es t hat ar e above t he t est t emper at ur e, t he
minimum t est pr essur e shall be calculat ed as f ollows, except t hat t he value
of ST / S shall not exceed 6.5:
PT =
1.5 PS T
S
wher e: PT = Minimum hydr ost at ic t est gauge pr essur e.
P = I nt er nal design gage pr essur e.
ST = Allowable st r ess at t est t emper at ur e.
S = Allowable st r ess at design t emper at ur e.
(c) I f t he t est pr essur e as def ined above would pr oduce a st r ess in excess
of t he yield st r engt h at t est t emper at ur e, t he t est pr essur e may be
r educed t o t he maximum pr essur e t hat will not exceed t he yield st r engt h at
t est t emper at ur e.
• Pneumat ic st r engt h t est s, when appr oved, shall beconduct ed per Par agr aph
345.5 of ASME/ ANSI B31.3. The t ight ness t est shall be per Par agr aph
345.5.4 of ASME/ ANSI B31.3. Only dur ing t he t ight ness t est shall t he
piping be appr oached and inspect ed f or leakage
Based on ASME/ ANSI B31.3, Par agr aph 345.5, f or pneumat ic leak t est s, t he
t est pr essur e is 110% of t he design pr essur e.
• Under gr ound pr essur e piping t hat is in pr ocess wat er ser vice and employs
non-welded gir t h j oint s (bell and spigot ) shall be st r engt h t est ed t o 1.5
t imes t he syst em design pr essur e pr ior t o backf illing. The t est pr essur e
shall be maint ained f or t wo hour s while t he j oint s ar e inspect ed f or leakage.
Page 63 of 111
I f f or oper at ional saf et y r easons t he line must be back-f illed, t hen t he
j oint s shall r emain exposed dur ing t est ing, or be subj ect ed t o a 24-hour
r ecor ded t est .
• Lube and seal oil piping shall be st r engt h t est edwit h t he ser vice f luid. The
t est pr essur e shall be 1.5 t imes t he design pr essur e or 690 kPa (ga) (100
psig), whichever is gr eat er .
• Low-pr essur e lines t hat ar e designed f or less t han 690 kPa (ga) (100 psig)
may be pneumat ically st r engt h t est ed. The pneumat ic st r engt h t est shall be
t he lesser of 110% of t he design pr essur e or 125% of t he nor mal oper at ing
pr essur e, but never less t han 170 kPa (ga) (25 psig). A t ight ness t est at 2135 kPa (ga) (3-5 psig) shall be conduct ed and t he piping checked f or leakage
wit h a soap solut ion.
• I nst r ument t ake-of f piping and sampling syst em piping, up t o t he f ir st
block valve, shall be st r engt h t est ed wit h t he piping or equipment t o which it
is connect ed.
• I nst r ument lead lines, bet ween t he f ir st block valve and t he inst r ument s t o
which t hey ar e connect ed, shall be subj ect ed t o t he same st r engt h t est as
t he piping or equipment t he inst r ument s ar e connect ed t o. Element s t hat
may be damaged shall be disconnect ed.
• Piping syst ems in vacuum ser vice shall be st r ength t est ed t o 100 kPa (ga)
(15 psig)
Par agr aph 345.4.3 of ASME/ ANSI B31.3 st at es t hat f or a hydr ost at ic t est
of piping wit h vessels as a syst em:
(a) Wher e t he t est pr essur e of piping at t ached t o a vessel is t he same as or
less t han t he t est pr essur e f or t he vessel, t he piping may be t est ed wit h t he
vessel at t he piping t est pr essur e.
(b) Wher e t he t est pr essur e of t he piping exceeds t he vessel t est pr essur e,
and it is not consider ed pr act ical t o isolat e t he piping f r om t he vessel, t he
piping and t he vessel may be t est ed t oget her at t he vessel t est pr essur e,
pr ovided t he owner appr oves and t he vessel t est pr essur e is not less t han
77% of t he calculat ed piping t est pr essur e.
Page 64 of 111
Cross- Count ry Pipelines
• Unless limit ed by f langes or valves in t he line,hydr ost at ic st r engt h t est
pr essur e of newly const r uct ed pipelines shall be calculat ed t o pr oduce a hoop
st r ess of 90% of t he SMYS of t he pipe mat er ial based on t he nominal wall
t hickness. The t est pr essur e at t he lowest point of t he pipeline, including
t he st at ic head, shall not r esult in a hoop st r ess gr eat er t han t he
SMYS. The st r engt h t est pr essur e shall be maint ained f or t wo hour s.
• The st r engt h t est t emper at ur e shall not r esult ina combined longit udinal
st r ess exceeding t he SMYS. The combined longit udinal st r ess is calculat ed
based on 0.7 hoop st r ess at t he t est pr essur e plus t emper at ur e st r ess plus
bending st r ess.
• Tight ness t est of newly const r uct ed pipelines shall be conduct ed at 95% of
t he st r engt h t est pr essur e immediat ely at t he complet ion of t he st r engt h
t est . The t ight ness t est pr essur e shall be maint ained long enough f or t he
inspect or t o examine all exposed j oint s. A 24-hour r ecor ded t ight ness t est
shall be applied when t he pipeline is bur ied or cover ed by insulat ion, or is
par t ially bur ied wit h a t ot al bur ied lengt h of mor e t han 300 m (1000 f t ).
• Wher e pr essur e var iat ions caused by t est -wat er t emper at ur e changes can
occur , such as in cr oss-count r y pipelines, a suf f icient number of
t her mocouples shall be inst alled t o obt ain accur at e pipe met al t emper at ur e
measur ement s t hat ar e r equir ed in or der t o det er mine t he accept ance of
t he pr essur e t est . The Consult ing Ser vices Depar t ment shall be consult ed
wit h r egar d t o any deviat ions t hat ar e not ed in t he 24-hour pr essur e char t .
St r engt h t est pr essur e of exist ing pipelines shall be per t he applicable
ASME/ ANSI B31.4 or B31.8 piping code based on t he Maximum Allowable
Oper at ing Pr essur e (MAOP) of t he pipeline. This is specif ied as f ollows:
(a) Por t ions of piping syst ems t o be oper at ed at a hoop st r ess of mor e t han
20% of t he specif ied minimum yield st r engt h of t he pipe shall be subj ect ed
at any point t o a hydr ost at ic pr oof t est equivalent t o not less t han 1.25
t imes t he int er nal design pr essur e at t hat point f or not less t han f our hour s.
When lines ar e t est ed at pr essur es which develop a hoop st r ess, based on
nominal wall t hickness, in excess of 90% of t he specif ied minimum yield
st r engt h of t he pipe, special car e shall be used t o pr event over st r ain of t he
pipe.
Page 65 of 111
P T = 1.25PD
wher e: PD = MAOP of limit ing component .
(1) Those por t ions of piping syst ems wher e all of t he pr essur ed component s
ar e visually inspect ed dur ing t he pr oof t est t o det er mine t hat t her e is no
leakage r equir e no f ur t her t est . This can include lengt hs of pipe, which ar e
pr e-t est ed f or use as r eplacement sect ions.
(2) On t hose por t ions of piping syst ems not visually inspect ed while under
t est , t he pr oof t est shall be f ollowed by a r educed pr essur e leak t est
equivalent t o not less t han 1.1 t imes t he int er nal design pr essur e f or not less
t han f our hour s.
(b) API RP 1110, Pr essur e Test ing of Liquid Pet r oleum Pipelines, may be used
f or guidance f or t he hydr ost at ic t est .
(c) The hydr ost at ic t est s shall be conduct ed wit h wat er , except liquid
pet r oleum t hat does not vapor ize r apidly may be used pr ovided:
(1) The pipeline sect ion under t est is not of f shor e and is out side of cit ies
and ot her populat ed ar eas, and each building wit hin 90 m (300 f t .) of t he
t est sect ion is unoccupied while t he t est pr essur e is equal t o or gr eat er t han
a pr essur e which pr oduces a hoop st r ess of 50% of t he specif ic minimum
yield st r engt h of t he pipe;
(2) The t est sect ion is kept under sur veillance by r egular pat r ols dur ing t est ;
and
(3) Communicat ion is maint ained along t he t est sect ion.
(d) I f t he t est ing medium in t he syst em will be subj ect t o t her mal expansion
dur ing t he t est , pr ovisions shall be made f or r elief of excess pr essur e.
Ef f ect s of t emper at ur e changes shall be t aken int o account when
int er pr et at ions ar e made of r ecor ded t est pr essur es.
(e) After completion of the hydrostatic test, it is important in cold
weather that the lines, valves, and fittings be drained completely of any
water to avoid damage due to f r eezing.
The above was t aken f rom t he Saudi Aramco Engineering Encyclopedia
Page 66 of 111
Page 67 of 111
Plidco Split Sleeves
Plidco split sleeves ar e used t o:
• Per manent ly r epair small split s, holes, or r upt ures which cannot be plugged
or pat ched r eadily and wher e downt ime f or dr aining oil f r om a line is
excessive.
• Pr ovide quick, t empor ar y r epair s wit hout weldingon ur gent ly r equir ed
pipelines, which can be r emoved f r om ser vice lat er f or per manent r epair s.
• Pr ovide t empor ar y r epair s t o pr ocess lines wit hinplant limit s wher e
economically j ust if ied. However , in t hese cases, sleeve pr essur e and
t emper at ur e limit at ions must be consider ed, and t he sleeve must be r emoved
f or per manent r epair in appr oximat ely t hr ee mont hs. As r ef er enced in
Figur e 6, t he split sleeve halves ar e posit ioned ar ound t he pipe such t hat t he
leak is locat ed bet ween t he t wo r ings of packing. When t he sleeves ar e
bolt ed, t he packing is compr essed against t he pipe sur f ace, which cont ains
t he leak. Plidco split sleeves ar e high in cost compar ed t o ot her met hods of
r epair . Ther ef or e, t heir use should be r est r ict ed t o t hose cases wher e
speed of r epair will pr ovide suf f icient economic j ust if icat ion SAEP-311
cont ains inst allat ion inst r uct ions, and pr essur e and t emper at ur e limit at ions
f or split sleeves. Split sleeves cannot be used t o connect t wo sect ions of
pipe.
HOT TAPS
I nspect ion Requirement s
The engineer r esponsible f or inspect ion must do t he f ollowing:
• I nspect weld ar eas, and 50 mm (2 in.) on each side of t hem, using
cont inuous ult r asonic examinat ion t o det er mine minimum pipe wall t hickness.
The measur ed t hickness must be at least t hat calculat ed f or t he hot t ap
condit ions, and no less t han 5 mm (0.2 in.).
• I dent if y laminat ions, cr acks or any discont inuit ei s in t he ar ea.
• Appr ove welding pr ocedur e.
• I nspect connect ion bef or e and dur ing inst allat ionf or compliance wit h
specif icat ion.
Page 68 of 111
• Conf ir m t hat hydr ost at ic t est pr essur e conf or ms to t hat specif ied.
• Wit ness and appr ove t he hydr ost at ic t est of equipment and connect ion.
• Conf ir m t hat t he connect ion is opened, dr ained, and vent ed af t er
complet ing hydr ost at ic t est .
• I nspect t he r emoved coupon. Evaluat e t he ext ent of header int er nal
cor r osion and ver if y wall t hickness.
Test ing Requirement s
The engineer r esponsible f or t est ing must apply t he f ollowing t est
r equir ement s:
• The hot -t ap machine must be per iodically pr essur et est ed based on GI
441.010 r equir ement s.
• The hot -t ap valve shall be pr essur e t est ed pr ior t o inst allat ion.
• Pr essur e t est t he br anch-t o-pipe weld, and t hen pr essur e t est t he f inal
br anch assembly.
• The r einf or cing pad of a welded br anch shall be test ed wit h air at 173 kPa
(25 psig) t hr ough a t apped vent hole.
• The pr essur e f or t he t est of t he hot -t ap connect oi n shall be 1.5 t imes t he
syst em design pr essur e (1.25 t imes f or cr oss-count r y pipelines), however ,
not t o exceed t he f ollowing: - The design hydr ost at ic t est pr essur e of t he
pipe or vessel being hot t apped, or - The minimum pr essur e in t he pipe or
vessel being hot t apped, while t he t est is in pr ogr ess, plus a calculat ed
dif f er ent ial pr essur e. The dif f er ent ial pr essur e shall be 1.25
t imes t he allowable ext er nal pr essur e calculat ed per t he ASME Code
Sect ion VI I I Division 1. The lengt h, L, t hat is used in t his calculat ion shall be
t he t ot al lengt h of a split t ee, or t he inside diamet er of t he welded nozzle,
based on t he act ual design det ail used.
• The t est pr essur e of t he hot -t ap connect ion may be lower t han t he or iginal
hydr ost at ic t est pr essur e. This is accept able since t he pur pose of t he t est
is t o pr ovide some assur ance of t he int egr it y of t he connect ion weld, not a
pr oof t est of t he weld. The syst em being t apped need not be down r at ed if a
lower t est pr essur e is used at a hot -t apped connect ion.
Page 69 of 111
Page 70 of 111
CONVERSION
FACTORS
8.0
Conver sion Fact or s
FRACTI ON OF I NCH
1/ 64
1/ 32
3/ 64
1/ 16
5/ 64
3/ 32
7/ 64
1/ 8
9/ 64
5/ 32
11/ 64
3/ 16
13/ 64
7/ 32
15/ 64
1/ 4
17/ 64
9/ 32
19/ 64
5/ 16
21/ 64
11/ 32
23/ 64
3/ 8
25/ 64
13/ 32
27/ 64
7/ 16
29/ 64
15/ 32
31/ 64
1/ 2
DECI MAL I NCHES
0.016
0.031
0.047
0.063
0.078
0.094
0.109
0.125
0.141
0.156
0.172
0.188
0.203
0.219
0.234
0.250
0.266
0.281
0.297
0.313
0.328
0.344
0.359
0.375
0.391
0.406
0.422
0.438
0.453
0.469
0.484
0.500
Page 71 of 111
MI LLI METERS
0.397
0.794
1.191
1.587
1.984
2.381
2.778
3.175
3.572
3.969
4.366
4.762
5.159
5.556
5.953
6.350
6.747
7.144
7.540
7.937
8.334
8.731
9.128
9.525
9.922
10.319
10.715
11.112
11.509
11.906
12.303
12.700
33/ 63
17/ 32
35/ 64
9/ 16
37/ 64
19/ 32
39/ 64
5/ 8
41/ 64
21/ 32
43/ 64
11/ 16
45/ 64
23/ 32
47/ 64
3/ 4
49/ 64
25/ 32
51/ 64
13/ 16
53/ 64
27/ 32
55/ 64
7/ 8
57/ 64
29/ 32
59/ 64
15/ 16
61/ 64
31/ 32
63/ 64
1
0.516
0.531
0.547
0.563
0.578
0.594
0.609
0.625
0.641
0.656
0.672
0.688
0.703
0.719
0.734
0.750
0.766
0.781
0.797
0.813
0.828
0.844
0.859
0.875
0.891
0.906
0.922
0.938
0.953
0.969
0.984
1.000
Page 72 of 111
13.097
13.494
13.890
14.287
14.684
15.081
15.478
15.875
16.272
16.668
17.065
17.462
17.859
18.256
18.653
19.050
19.447
19.843
20.240
20.637
21.034
21.431
21.828
22.225
22.621
23.018
23.415
23.812
24.209
24.606
25.003
25.400
I nches
I nches
I nches
Feet
Miles
Squar e I nches
Squar e Feet
Cubic I nches
U.S. Gallons
Pounds
Ounce Avoir
BTU
ENGLI SH TO METRI C
TO
Millimet er s
Cent imet er s
Met er s
Met er s
Kilomet er s
Squar e Cent imet er s
Squar e Met er s
Cubic Cent imet er s
Lit er s
Kilogr ams
Gr ams
Calor ies
MULTI PLY BY
25.4
2.54
0.0254
0.3048
1.609347
6.452
0.0929
16.3872
3.7854
.45359
28.3495
252
TO CHANGE
Millimet er s
Cent imet er s
Met er s
Met er s
Kilomet er s
Squar e Cent imet er s
Squar e Met er s
Cubic Cent imet er s
Cubic Met er s
Lit er s
Kilogr ams
Gr ams
Calor ies
METRI C TO ENGLI SH
TO
I nches
I nches
I nches
Feet
Miles
Squar e I nches
Squar e Feet
Cubic I nches
Cubic Feet
U.S. Gallon
Pounds
Ounces Avoir
BTU
MULTI PLY BY
.03937
.39371
39.371
3.281
.62137
.1550
10.7649
.061
35.314
.26417
2.20462
.03527
.003968
TO CHANGE
Page 73 of 111
TO CHANGE
Cubic Feet
Cubic I nches
Cubic Feet
Gallons
Cubic I nches
Gallons
Bar r els
Gallons
I mper ial Gallons
U.S Gallons
Squar e Feet
Squar e I nches
Long Tons
Shor t Tons
Long Tons
MEASURE
TO
Cubic I nches
Cubic Feet
Gallons
Cubic Feet
Gallons
Cubic I nches
Gallons
Bar r els
U.S. Gallons
I mper ial Gallons
Squar e I nches
Squar e Feet
Pounds
Pounds
Shor t Tons
PRESSURE
TO
MULTI PLY BY
1728
.00058
7.480
.1337
.00433
231
42
.0238
1.2009
.8326
144
.00695
2240
2000
1.12
TO CHANGE
Pounds per Squar e I nch
Pounds per Squar e I nch
Pascals
Kilogr ams per Squar e CM
Pascals
Kilogr ams per Squar e CM
Pounds per Squar e I nch
Pounds per Squar e I nch
MULTI PLY BY
6.895 x 10 3
7.03 x 10 -2
1.45 x 10 -4
1.422 x 10 1
TO CHANGE
Cent igr ade
Cent igr ade
Fahr enheit
Fahr enheit
TEMPERATURE
TO
Kelvin
Fahr enheit
Cent igr ade
Kelvin
MULTI PLY BY
1.0 + 273
1.8 + 17.78
-32 x 0.555
-32 x 0.555 + 273.15
Page 74 of 111
8.0
9.0
b
Area = ab
a
h
b
Area =
bh
2
Area = πab
a
b
(
Circ. = π 2 a 2 + b 2
a = 2.598a 2
a
r
d
Circ. = 2πr
or
Circ. = πd
Area = πr 2
Page 75 of 111
)
c
Tot al Sur f ace Ar ea (S)
d
S = 2πr (r + h )
Volume
h
r
V = πr 2 h
or
c 2h
V=
4π
Page 76 of 111
INSPECTION
TERMINOLOGY
9.0
I nspect ion Ter minology
GLOSSARY (Saudi Aramco Eng Encyclopedia)
angle t est ing An ult r asonic t est met hod in which t r ansmission is at an angle
t o t he t est sur f ace.
back ref lect ion The ult r asonic signal r eceived f r om t he back sur f ace of a
t est obj ect .
The action by which liquid penetrants flow out of a
discontinuity, due primarily to capillary action and the blotting effect of
the developer.
bleed out
blowhole A hole in a cast ing or weld caused by gas ent r apped dur ing
solidif icat ion.
blot t ing The act ion of a developer in dr awing out liquid penet r ant f r om a
sur f ace discont inuit y causing maximum bleed out f or incr eased cont r ast and
sensit ivit y.
capillary act ion The t endency of cer t ain liquid t o t r avel, climb, or dr aw int o
t ight cr ack-like int er f ace ar eas due t o such pr oper t ies as sur f ace t ension,
wet t ing, cohesion, adhesion, and viscosit y.
Cat egory D Fluid Service As def ined in ASME/ ANSI B31.3, a f luid ser vice
in which all t he f ollowing apply: t he f luid handled is nonf lammable, nont oxic,
and not damaging t o human t issues as def ined in Par agr aph 300.2; t he design
gage pr essur e does not exceed 1,030 kPa (150 psi); and (3) t he design
t emper at ur e is f r om -29°C t hr ough 186°C (-20° F t hr ough 366°F).
Cat egory M Fluid Service As def ined in ASME/ ANSI B31.3, a f luid ser vice
in which t he pot ent ial f or per sonnel exposur e is j udged t o be signif icant and
in which a single exposur e t o a ver y small quant it y of a t oxic f luid, caused by
leakage, can pr oduce ser ious ir r ever sible har m t o per sons on br eat hing or
bodily cont act , even when pr ompt r est or at ive measur es ar e t aken.
Page 77 of 111
cold crack A f law t hat appear s as a st r aight line, usually cont inuous
t hr oughout it s lengt h, and gener ally singly. These cr acks st ar t at t he
sur f ace.
couplant A subst ance used bet ween an ult r asonic t r ansducer f ace and t he
t est sur f ace t o per mit or impr ove t r ansmission or r ecept ion.
crack A mat er ial separ at ion t hat has a r elat ively lar ge cr oss-sect ion in one
dir ect ion and a small or negligible cr oss-sect ion when viewed in a dir ect ion
per pendicular t o t he f ir st .
def ect A discont inuit y whose size, shape, or ient at ion, locat ion, or pr oper t ies
make it det r iment al t o t he usef ul ser vice of t he par t in which it occur s, or
which exceeds t he accept / r ej ect cr it er ia of t he par t icular design.
developer A f inely divided mat er ial applied over t he sur f ace of a par t t o
help br ing out penet r ant indicat ions.
discont inuit y Any int er r upt ion in t he nor mal physical st r uct ur e or
conf igur at ion of a par t such as cr acks, laps, seams, inclusions, or por osit y. A
discont inuit y may or may not af f ect t he usef ulness of t he par t .
dry powder Finely divided f er r omagnet ic par t icles select ed and pr epar ed
f or magnet ic par t icle inspect ion by t he dr y met hod.
examinat ion Applies t o qualit y cont r ol f unct ions per f or med by t he
manuf act ur er , f abr icat or , or er ect or .
f alse indicat ion An indicat ion t hat may be int er pr et ed incor r ect ly as a
discont inuit y or a def ect ; a non-r elevant indicat ion.
f illed crack A cr ack open t o t he sur f ace but f illed wit h some f or eign
mat er ial, such as oxide, gr ease, et c.
f law An imper f ect ion, which may not be har mf ul. I f har mf ul, it is a def ect
or discont inuit y.
f lux lines I maginar y lines used t o explain t he behavior of magnet ic f ields.
f usion The complet e j oining of t wo par t s in such a manner t hat loads ar e
ef f ect ively t r ansf er r ed acr oss t heir common boundar y.
hot crack A f law t hat appear s as a r agged dar k line of var iable widt h and
numer ous br anches. I t has no cont inuit y, may exist in gr oups, and may
or iginat e int er nally or at t he sur f ace.
hot t ear A f r act ur e f or med in a met al dur ing solidif icat ion.
indicat ion An r esponse t hat r equir es int er pr et at ion t o det er mine it s
signif icance.
Page 78 of 111
inspect ion The pr ocess of examining and checking mat er ials and par t s f or
possible def ect s, or deviat ion f r om accept ance st andar ds.
int erpret at ion The pr ocess of det er mining t he nat ur e of an indicat ion.
magnet A mat er ial having t he power t o at t r act ir on and ot her subst ances t o
it self and exhibit polar it y.
magnet ic f lux The t ot al number of magnet ic lines exist ing in a magnet ic
cir cuit .
Magnet ic discont inuit y A br eak in t he magnet ic cont inuit y of a par t ,
possibly caused by a def ect .
Nondest ruct ive examinat ion Test ing t o det ect int er nal, sur f ace, or
concealed def ect s or f laws in a mat er ial using t echniques t hat do not damage
t he it em being t est ed.
Non- relevant indicat ions These ar e t r ue indicat ions pr oduced by
uncont r olled or incor r ect t est condit ions. They have no r elat ion t o
discont inuit ies t hat might be def ect s.
normal f luid service As def ined in ASME/ ANSI B31.3, a f luid ser vice
per t aining t o most piping cover ed by t his Code, i.e., not subj ect t o t he r ules
f or Cat egor y D, Cat egor y M, or High-Pr essur e Fluid Ser vice, and not subj ect
t o sever e cyclic condit ions.
pores Small voids in t he body of a met al.
porosit y chart s St andar d char t s f or compar ing por osit y size, spacing, and
number in a given ar ea.
pressure- cont aining weld A weld t hat j oins t wo pr essur e-cont aining
component s such as at a br anch connect ion.
prods Two hand-held elect r odes, which ar e pr essed against t he sur f ace of a
par t t o make cont act f or passing magnet izing cur r ent t hr ough t he met al.
radiography The use of r adiant ener gy in t he f or m of neut r ons, x-r ays or
gamma r ays f or NDE of opaque obj ect s. I t pr oduces gr aphical r ecor ds on
sensit ized f ilms, which indicat e t he compar at ive soundness of t he obj ect
being t est ed.
Ref erence radiographs A gr oup of r adiogr aphs cont aining images of
discont inuit ies. They ar e used as compar ison st andar ds f or mat er ial
accept abilit y.
severe cyclic condit ions As def ined in ASME/ ANSI B31.3, t hose in which
SE, comput ed in accor dance wit h Par agr aph 319.4.4, exceeds 0.8SA (as
def ined in Par agr aph 302.3.5), and t he equivalent number of cycles (N in
Page 79 of 111
par agr aph 302.3.5) exceeds 7000; or ot her condit ions which t he designer
det er mines will pr oduce an equivalent ef f ect .
suspension The liquid bat h in which f er r omagnet ic par t icles used in t he wet
met hod ar e suspended.
void Discont inuit y in which t her e is a physical separ at ion bet ween opposit e
walls.
wet met hod The magnet ic par t icle inspect ion met hod employing
f er r omagnet ic par t icles suspended in a light oil or wat er , which act s as a
vehicle.
Page 80 of 111
PRESSURE VESSELS
10.0
Vessels
PRESSURE VESSELS
Ret ir ement Thickness:
I t is advisable t o use t he saf et y inst r uct ion sheet (SI S) of t he vessel
t o det er mine t he r et ir ement t hickness, as in most cases t he calculat ion
may be complex.
Ther ef or e, pr ior t o a pr essur e vessel inspect ion, t he inspect or should
obt ain a copy of t he SI S f or t he equipment .
Thickness of Shell Under I nt er nal
Pr essur e:
Cylindr ical
Shell:
Choose t he Gr eat er of (1) and (2)
Below:
(1)
PR
t =
SE - 0.6 P
(2)
P=
or
PR
t =
SEt
R + 0.6 t
2 SEt
R – 0.4 t
2 SE + 0.4 P
or
Spher ical
Shell:
(3)
t =
PR
2 SE – 0.2 P
t =
R=
Minimum t hickness
I nside r adius
E=
J oint ef f iciency
P=
S=
P=
or
2 SEt
R – 0.2 t
Design pr essur e, (PSI )
Maximum allowable
st r ess value
of t he mat er ial (PSI )
Page 81 of 111
Condit ions f or (1) above:
T
Does not exceed ½ R or P does not exceed 0.385
SE
Condit ions f or (2) above:
t
Does not exceed ½ R or P does not exceed 1.25
SE
Condit ions f or (3) above:
t
Does not exceed 0.356 R or P does not exceed
0.665 SE
Thicknesses of shells under ext er nal pr essur e see ASME Sec. VI I I Par a.
UG-28)
(For condit ions exceeding t he above limit s, see ASME sec. VI I I
Div.1Appendix –1)
Thickness of Formed Heads Under Internal Pressure (Pressure on Concave Side)
Refer to the following figure for the typical types of heads and their dimensions
ASME SECTION VIII - DIVISION 1
t
D
t
L
h
L
r
D
t
D
(a) Ellipsoidal
(c) Hemispherical
(b) Spherically Dished
(Torispherical)
D
L
D
r
α
t
t
D1
α
t
(d) Conical
(e) Toriconical
(Cone Head With Knuckle)
Page 82 of 111
(1)
Ellipsodial Heads
PD
2SE - 0.2P
t=
or
2SEt
R + 0.2t
Tor ispher ical
(2)
0.885PL
t=
or
SE - 0.1P
SEt
0.885L + 0.1t
Hemispher ical
(3)
t=
PL
2SE - 0.2P
or
2SEt
L + 0.2t
PD
2 cos α (SE- 0.6P)
or
2Set α
D + 1.2t cos α
Conical
(4)
t=
Toriconical
(5)
t
f or t he conical sect ion – use f or mula (4) above using Di in place of
D
Di = D – 2 r (1 – cos α)
t
f or t he knuckle sect ion – use f or mula (3) above in which,
L=
Di
2 cos α
Page 83 of 111
Condit ions For t he Above For mulae:
For (1)
above:
Not e:
For (2)
above:
Not e:
For (3)
above:
Half t he minor axis = 1/ 4 of t he I D of t he head
skir t
Appr oximat e values of knuckle r adius and spher ical
r adius of a 2.1 ellipsoidal head ar e 0.17 D and 0.90 D,
r espect ively.
Knuckle r adius = 6% of inside cr own r adius
I nside cr own r adius = out side Dia. of skir t
For mat er ials having t ensile st r engt h gr eat er t han
80,000 PSI , use S = 20,000 PSI at r oom
t emper at ur e.
t does not exceed 0.356 L
or
P does not exceed 0.665 SE
For (4)
above:
Half apex angle α is not gr eat er t han 30 degr ees
Knuckle r adius is neit her less 6% of t he OD of
t he head skir t nor less t han t hr ee t imes t he
knuckle t hickness
Tor iconical heads may be used when α ≤ 30 degr ees,
but ar e mandat or y f or conical head design when α
exceeds 30 degr ees
For Tor iconical Heads:
Not e:
Page 84 of 111
Thickness of Heads Under Ext er nal Pr essur e (Pr essur e on Convex Side)
Shall be calculat ed per ASME Sec. VI I I Div. 1, Par a. UG-33
Minimum Thickness of Nozzle Neck
I n most cases, t he r et ir ement t hickness of a nozzle neck shall be t he
minimum t hickness of a st andar d wall pipe (List ed in t able 2 of ANSI B
36-10 less 12-½ %).
See ASME Sec. VI I I Div. 1, Par a. UG-45 f or det ails.
Page 85 of 111
FITTINGS
11.0
Fit t ings
Y
O
Welding Neck Flanges
Nom
Pipe
Size
1
/2
/4
1
1 1 /4
1 1 /2
2
2 1 /2
3
3 1 /2
4
5
6
8
10
12
14
16
18
20
22
24
26
30
34
36
42
3
150 LB.
300 LB.
400 LB.
Length
Outside
Length
Outside
Length
Outside
Thru
Diam Of
Thru
Diam Of
Thru
Diam Of
Hub
Flange
Hub
Flange
Hub
Flange
Y (2)
O
Y (1)
O
Y (1)
O
1
7
3
1
For
3 /2
1 /8
3 /4
2 /16
7
1
5
1
Sizes
3 /8
2 /16
4 /8
2 /4
3 1 /2
4 1 /4
2 3/16
4 7 /8
2 7/16
and
2 9/16
5 1 /4
2 1 /4
4 5 /8
11
1
7
smaller
2 /16
6 /8
2 /16
5
3
1
1
use
2 /4
6 /2
2 /2
6
600 Lb.
3
7 1 /2
2 3 /4
7
standard
3 1 /8
8 1 /4
2 3 /4
7 1 /2
8 1 /2
3 3/16
9
2 13/16
3 3 /8
10
3
9
3 1 /2
10
3 7 /8
11
3 1 /2
10
4
11
3 7 /8
12 1/2
3 1 /2
11
4 1/16
12 1/2
15
4
13 1/2
15
4 3 /8
4 5 /8
5
1
1
4 /8
4 7 /8
17 /2
17 /2
4
16
4 1 /2
5 1 /8
5 3 /8
20 1/2
20 1/2
19
5 5 /8
5 7 /8
23
23
5
21
3
1
1
1
5 /4
6
5
25 /2
25 /2
23 /2
1
1
5 /2
6 /4
6 1 /2
28
28
25
1
3
1
11
1
6 5 /8
30 /2
6 /8
30 /2
5 /16
27 /2
6 3 /4
33
6 1 /2
33
5 7 /8
29 1/2
6 7 /8
36
6 5 /8
36
6
32
1
1
1
1
7 5 /8
38 /4
7 /4
38 /4
5
34 /4
8 5 /8
43
8 1 /4
43
5 1 /8
38 3/4
43 3/4
5 5/16
47 1/2
9 1 /8
47 1/2
9 1 /2
3
1
46
5 /8
50
9 /2
50
9 7 /8
53
5 5 /8
57
10 7/8
57
11 3/8
(1)
The 1/16" raised face is included in “Length thru Hub ‘Y’.”
(2) The 1/4" raised face is not included in “Length thru Hub ‘Y’.”
Page 86 of 111
600 LB.
Length
Outside
Thru
Diam Of
Hub
Flange
Y (2)
O
3
1
3 /4
2 /16
5
1
4 /8
2 /4
4 7 /8
2 7/16
5 1 /4
2 5 /8
1
2 3 /4
6 /8
2 7 /8
6 1 /2
3 1 /8
7 1 /2
3 1 /4
8 1 /4
3 3 /8
9
4
10 3/4
4 1 /2
13
4 5 /8
14
1
16 /2
5 1 /4
6
20
6 1 /8
22
6 1 /2
23 3/4
7
27
1
29 /4
7 1 /4
7 1 /2
32
7 3 /4
34 1/4
8
37
8 3 /4
40
9 3 /4
44 1/2
49
10 5/8
3
51 /4
11 1/8
58 3/4
12 3/4
Y
O
Y
Y
O
O
Slip-On, Threaded, And Socket Type Flanges
Nom
Pipe
Size
1
/4
/8
/2
3
/4
1
1 1 /4
1 1 /2
2
2 1 /2
3
3 1 /2
4
5
6
8
10
12
14
16
18
20
22
24
26
30
34
36
42
3
1
150 LB.
Length
Outside
Thru
Diam
Hub
Y (1)
O
5
3 1 /2
/8*t
1
5
3 /2
/8*t
5
3 1 /2
/8
5
/8
3 7 /8
11
/16
4 1 /4
13
/16
4 5 /8
7
/8
5
1
6
1 1 /8
7
1 3/16
7 1 /2
1 1 /4
8 1 /2
1 5/16
9
1 7/16
10
1 9/16
11
1
1 3 /4
13 /2
16
1 15/16
2 3/16
19
21
2 1 /4
2 1 /2
23 1/2
2 11/16
25
27 1/2
2 7 /8
1
3 1/8✝✜
29 /2
3 1 /4
32
3 3/8✝✜
34 1/4
3 1/2✝✜
38 3/4
3
43 /4
3 11/16✝✜
46
3 3/4✝✜
4 ✝✜
53
300 LB.
400 LB.
Length
Outside
Length
Outside
Thru
Diam
Thru
Diam
Hub
Hub
Y (2)
O
Y (1)
O
7
3 3 /4
/8*t
3
7
For
3 /4
/8*t
7
Sizes
3 3 /4
/8
3 1 /2
4 5 /8
1
and
4 7 /8
1 1/16
smaller
1 1/16
5 1 /4
3
1
use
1 /16
6 /8
600 Lb.
1 5/16
6 1 /2
standard
1 1 /2
7 1 /2
1 11/16
8 1 /4
1 3 /4
9
1 7 /8
10
2✜
10
2✜
11
2 1/8✜
11
7
1
1
3 /8✜
12 /2
2 1/4✜
12 /2
3
15
2 11/16✜
15
4 /8✜
17 1/2
17 1/2
2 5/8✜
2 7/8✜
20 1/2
20 1/2
2 7/8✜
3 1/8✜
23
23
3✜
3 5/16✜
1
1
1
3 /4✜
25 /2
3 11/16✜
25 /2
3 1/2✜
28
3 7/8✜
28
4✜
30 1/2
3 3/4✜
30 1/2
4 1/4✝✜
33
4✝✜
33
4 1/2✜
36
4 3/16✜
36
7 5/8✝✜
38 1/4
7 1/4✝✜
38 1/4
8 5/8✝✜
43
8 1/4✝✜
43
1
1
1
47 /2
9 /8✝✜
47 /2
9 1/2✝✜
1
50
9 /2✝✜
50
9 7/8✝✜
10 7/8✝✜
11 3/8✝✜
57
57
* Not available in Slip-on type.
✝ Not available in Threaded type.
✜Not available in Socket type.
Page 87 of 111
600 LB.
Outside
Length
Diam
Thru
O
Hub
Y (2)
7
3 3 /4
/8*t
3
7
3 /4
/8*t
7
3 3 /4
/8
4 5 /8
1
4 7 /8
1 1/16
1 1 /8
5 1 /4
1 1 /4
6 1 /8
1 7/16
6 1 /2
1 5 /8
7 1 /2
1
1 13/16
8 /4
1 15/16
9
2 1/8✜
10 3/4
2 3/8✜
13
2 5/8✜
14
1
16 /2
3✜
20
3 3/8✜
22
3 5/8✜
3
23 /4
3 11/16✜
27
4 3/16✜
29 1/4
4 5/8✜
5✜
32
5 1/4✝✜
34 1/4
5 1/2✜
37
8 3/4✝✜
40
9 3/4✝✜
44 1/2
49
10 5/8✝✜
3
51 /4
11 1/8✝✜
58 3/4
12 3/4✝✜
Q
O
1/
"
16
Blind Flanges
/2
/4
1
1 1 /4
1 1 /2
150 LB.
Outside
Thick
Diam Of
ness
Flange
Q (1)
O
7
3 1 /2
/16
1
3 7 /8
/2
9
4 1 /4
/16
5
5
/8
4 /8
11
/16
5
2
2 1 /2
3
3 1 /2
4
6
7
7 1 /2
8 1 /2
9
3
/4
7
/8
15
5
6
8
10
12
14
16
18
20
22
24
26
30
34
36
42
10
11
13 1/2
16
19 1/2
21
23 1/2
25
27 1/2
29 1/2
32
34 1/4
38 3/4
43 3/4
46
53
15
Nom
Pipe
Size
1
3
15
15
/16
/16
/16
/16
1
1 1 /8
1 3/16
1 1 /4
1 3 /8
1 7/16
1 9/16
1 11/16
1 13/16
1 7 /8
2
2 1 /8
2 5/16
2 3 /8
2 5 /8
300 LB.
Outside
Thick
Diam Of
ness
Flange
Q (1)
O
9
3 3 /4
/16
5
4 5 /8
/8
11
4 7 /8
/16
3
1
/4
5 /4
13
6 1 /8
/16
400 LB.
Outside
Thick
Diam Of
ness
Flange
Q (2)
O
For
Sizes
3 1 /2
and
smaller
use
600 Lb.
standard
7
6 1 /2
7 1 /2
8 1 /4
9
10
/8
1
1 1 /8
1 3/16
1 1 /4
11
12 1/2
15
17 1/2
20 1/2
23
25 1/2
28
30 1/2
33
36
38 1/4
43
47 1/2
50
57
1 3 /8
1 7/16
1 5 /8
1 7 /8
2
2 1 /8
2 1 /4
2 3 /8
2 1 /2
2 5 /8
2 3 /4
3 1 /8
3 5 /8
4
4 1 /8
4 5 /8
10
11
12 1/2
15
17 1/2
20 1/2
23
25 1/2
28
30 1/2
33
36
38 1/4
43
47 1/2
50
57
Page 88 of 111
1 3 /8
1 1 /2
1 5 /8
1 7 /8
2 1 /8
2 7 /8
2 3 /8
2 1 /2
2 5 /8
2 3 /4
2 7 /8
3
3 1 /2
4
4 3 /8
4 1 /2
5 1 /8
600 LB.
Outside
Thick
Diam Of
ness
Flange
Q (2)
O
9
3 3 /4
/16
5
4 5 /8
/8
11
4 7 /8
/16
13
1
/16
5 /4
7
6 1 /8
/8
6 1 /2
7 1 /2
8 1 /4
9
10 3/4
1
1 1 /8
1 1 /4
1 3 /8
1 1 /2
13
14
16 1/2
20
22
23 3/4
27
29 1/4
32
34 1/4
36
40
44 1/2
49
51 3/4
58 3/4
1 3 /4
1 7 /8
2 3/16
2 1 /2
2 5 /8
2 3 /4
3
3 1 /4
3 1 /2
3 3 /4
4
4 1 /4
4 1 /2
4 3 /4
4 7 /8
5 1 /2
SAES-L-009 also list s st andar d Saudi Ar amco dr awings t hat pr ovide
mandat or y dimensional st andar ds f or specif ic size r anges, r at ings, f lange
t ypes, and f acings.
These st andar d f langes must be used as applicable wit hin t heir def ined
scopes, even if API -605, MSS-SP-44, or ASME/ ANSI B16.47 has t he same
designat ions.
These st andar d dr awings ar e as f ollows:
NPS
Range Class
Type Facing
26-60
150
WN RF
26-60
300
WN RF
26-48
300
WN RJ
54-60
300
WN RJ
30-48
400
WN RF
26-48
600
WN RF
26-48
600
WN RJ
26-48
300
Lap RJ
54-60
300
Lap RJ
26-48
600
Lap RJ
54-60
75
Blind RF
wher e:
WN = Weld neck.
RF = Raised f ace.
RJ = Ring j oint .
Lap = Lapped f lange.
Blind = Blind f lange.
Page 89 of 111
St andar d Dr awing
AD-036634
AD-036991
AC-036484
AC-036437
AD-036698
AD-036673
AC-036442
AC-036486
AE-036438
AC-036443
AD-036696
CODES
&
STANDARDS
12.0
Codes & St andar ds
Typical const r uct ion codes in use int er nat ionally ar e:
•
Amer ican Societ y of Mechanical Engineer s Boiler and Pr essur e Vessel
Code (ASME-BPVC).
•
Amer ican Pet r oleum I nst it ut e (API 650- St or age Tanks)
•
Br it ish St andar ds (BS5500 Pr essur e Vessels)
•
AD-Mer kblat t (Ger man Pr essur e Vessel Code)
•
TRD (Ger man Boiler Code, nor mally r ead in conj unct ion wit h VGB
Dir ect ives).
•
CODAP (Fr ance)
•
St oomwezen (Net her lands)
•
ASME 31.1- Boiler Piping Code
•
ASME 31.3 – Chemical Piping
•
ASME 31.4- Gas t r anspor t at ion piping
•
ASME 31.8- Liquid Hydr ocar bon t r anspor t at ion piping.
The Eur opean codes ar e cur r ent ly under r eview and t he f ollowing pr oduct
st andar ds will event ually super cede t he exist ing Nat ional St andar ds:
•
CEN/ TC54 Unf ir ed Pr essur e Vessels
•
CEN/ TC267 I ndust r ial Piping
•
CEN/ TC269 Boiler s.
Saudi Ar amco nor mally uses t he ASME-BPVC Const r uct ion codes such as
ASME VI I I Division 1 and 2 f or pr essur e vessels and ASME 1 f or Boiler s.
The main dif f er ence bet ween ASME VI I I Division 1 and 2 is t hat 1 cur r ent ly
has a Fact or of Saf et y (FOS) of f our (under consider at ion t o change t o 3.5)
and 2 has a FOS of t hr ee. Most of t he Eur opean codes ar e based on a FOS
of t hr ee. That is why ASME VI I I Division 2 and t he Eur opean Const r uct ion
codes nor mally st ipulat e higher qualit y mat er ials, and in t ur n a gr eat er level
of non-dest r uct ive t est ing. The ASME Const r uct ion Codes ar e suppor t ed by
ot her sect ions such as ASME V (Non-dest r uct ive Test ing), ASME I X
(Welding), et c. When a vessel is const r uct ed by an ASME r egist er ed
manuf act ur er , in accor dance wit h t he ASME code under t he auspices of a
valid commissioned Aut hor ized I nspect or (Nat ional Boar d of Boiler and
Pr essur e Vessel I nspect or s) t he vessel can be st amped as being in
accor dance wit h t he ASME Code. Vessels not r equir ed t o be code st amped
Page 90 of 111
(U) but ar e built using t he ASME codes ar e said t o be built “Gener ally in
accor dance wit h t he ASME Code”. This nor mally means t hey have f ollowed
t he design, mat er ials, t est ing r equir ement s but have not f ollowed t he Code
r ules f ully (i.e. no Aut hor ized I nspect or ), t hese vessels ar e not ASME
pr essur e vessels and ar e not st amped, t he U1 dat a f or m when complet ed will
lack t he Aut hor ized I nspect or s agr eement t hat it complies wit h t he code
and accept ance is based on alt er nat ive wor ding.
Repair s or modif icat ions t o ASME pr essur e vessels t hat have seen ser vice,
when such r epair s or modif icat ions ar e not under t he auspices of an
Aut hor ized I nspect or means t hat t he vessels ar e no longer ASME pr essur e
vessels but r emain “pr essur e vessels gener ally built in accor dance wit h t he
ASME code” unless such r epair s ar e conduct ed by an owner -user wit h “R”
st amp appr oval.
Typical codes and st andar ds t hat addr ess pr essur e equipment t hat has seen
ser vice ar e:
•
•
•
•
ANSI / NB-23 Nat ional Boar d I nspect ion Code
API 510 Pr essur e Vessels.
API 570 Pr ocess Piping.
API 653 St or age Tanks.
Review of t he SAES/ SAEP and SAI P includes a number of document s t hat
r ef er ence t he above document s and t ypical document s t hat t he I nspect or
should ut ilize dur ing t he cour se of his wor k include:
SAES-A-004
SAES-A-007
SAES-A-206
SAES-B-005
SAES-D-001
SAES-D-100
SAES-D-108
SAES-D-109
SAES-E-004
SAES-E-006
Gener al Requir ement s f or Pr essur e Test ing
Hydr ost at ic Test ing Fluids and Lay-up Pr ocedur es
Posit ive Mat er ial I dent if icat ion
Spacing and Diking f or At mospher ic and Low Pr essur e Tanks
Design Cr it er ia f or Pr essur e Vessels
Design Cr it er ia of At mospher ic and Low Pr essur e Tanks
St or age Tank I nt egr it y
Design of Small Tanks
Design Cr it er ia of Shell and Tube Heat Exchanger s
Design Cr it er ia of Double Pipe Heat Exchanger s
Page 91 of 111
SAES-E-007
SAES-E-014
SAES-E-015
SAES-F-001
SAES-F-007
SAES-H-001
SAES-H-002
SAES-H002V
SAES-H-101
SAES-H-101V
SAES-H-200
SAES-H-201
SAES-H-203
SAES-H-204
SAES-H204V
SAES-L-001
SAES-L-002
SAES-L-003
SAES-L-004
SAES-L-005
SAES-L-006
SAES-L-007
SAES-L-008
SAES-L-009
SAES-L-010
SAES-L-011
SAES-L-012
SAES-L-022
SAES-L-032
SAES-L-033
SAES-L-041
Design Cr it er ia of Air Cooled Heat Exchanger s
Design Cr it er ia of Plat e and Fr ame Heat Exchanger s
Design Cr it er ia of Elect r ic Heat Exchanger s
Design Cr it er ia of Fir ed Heat er s
Design Cr it er ia of Flar es
Select ion Requir ement s f or I ndust r ial Coat ings
I nt er nal and Ext er nal Coat ings f or St eel Pipelines and Piping
Appr oved Saudi Ar amco Dat a Sheet s
Appr oved Pr ot ect ive Coat ing Syst ems
Appr oved Saudi Ar amco Dat a Sheet s- Paint s and Coat ings
St or age, Handling and I nst allat ion of Pipe Ext er nally Coat ed wit h
Fusion Bonded Epoxy or Polyet hylene
Gener al Specif icat ion f or Over -The-Dit ch Ext er nal FBE
Coat ing of Field Gir t h Welds
Hand Applied Tape-Wr apping of Bur ied Pipe
Gener al Specif icat ion f or Applying Heat -Shr ink Sleeves t o
Coat ed Pipe
Appr oved Vendor I nst allat ion Pr ocedur es f or Heat -Shr ink Sleeves
Basic Cr it er ia f or Piping Syst ems
Design Condit ions f or Pr essur e Piping
Design St r ess Cr it er ia f or Pr essur e Piping
Pr essur e Design of Piping Component s
Piping Mat er ial Specif icat ions
Met allic Pipe Select ion
Select ion of Met allic Pipe Fit t ings
Select ion of Valves
Met allic Flanges, Gasket s and Bolt s f or Low and I nt er mediat e
Temper at ur e Ser vice
Limit at ions on Piping J oint s
Flexibilit y, Suppor t and Anchor ing of Piping
Design of Piping Syst ems inside Plant Ar eas
Design of Wellhead Piping, Flowlines, Tr unklines and Test lines
Mat er ial Select ion of Piping Syst ems
Cor r osion Pr ot ect ion Requir ement s f or Pipelines/ Piping
Ut ilit y Piping Connect ions t o Pr ocess Equipment
Page 92 of 111
SAES-L-042
SAES-L-043
SAES-L-044
SAES-L-045
SAES-L-046
SAES-L-047
SAES-L-050
SAES-L-051
SAES-L-052
SAES-L-056
SAES-L-060
SAES-L-062
SAES-L-070
SAES-N-100
SAES-N-110
SAES-W -010
SAES-W -011
SAES-W -012
SAES-W -014
SAES-W -015
SAES-W -016
SAES-W -017
SAES-X -400
SAES-X -500
SAES-X -600
SAES-X -700
Plant Ut ilit y St at ions
Ther mal Expansion Relief in Piping
Anchor s f or Cr oss-Count r y Pipelines
Scr aper Tr ap St at ion Piping and Appar at us
Pipeline Cr ossings Under Roads and Railr oads
Valve Boxes
Const r uct ion Requir ement s f or Met allic Plant Piping
Const r uct ion Requir ement s f or Cr oss-Count r y Pipelines
Hot Tap Connect ions
Pr essur e Test ing of Plant Piping and Pipelines
Nonmet allic Piping
Technically Accept able Class 04 Valve Manuf act ur er s
Technically Accept able Manuf act ur er s of API 6A 10000 PSI
Gat e Valves and Chokes
Ref r act or y Syst ems
I nst allat ion Requir ement s- Cast able Ref r act or ies
Welding Requir ement s f or Pr essur e Vessels
Welding Requir ement s f or On-Plot Piping
Welding Requir ement s f or Pipelines
Weld Over lays and Welding of Clad Mat er ials
St r ip Lining Applicat ion
Welding of Cor r osion Resist ant Mat er ials
Welding Requir ement s f or API Tanks
Cat hodic Pr ot ect ion of Bur ied Pipelines
Cat hodic Pr ot ect ion of Vessel and Tank I nt er nals
Cat hodic Pr ot ect ion of Plant Facilit ies
Cat hodic Pr ot ect ion of Onshor e Well Casings
SAEPSAEPSAEPSAEPSAEPSAEPSAEPSAEPSAEP-
Equipment I nspect ion Schedule
Evaluat ing The Remaining St r engt h of Cor r oded Pipelines
Oper at ions I nspect ion Unit Reviews
I nspect ion of Communit y and Oper at ions Suppor t Facilit ies
Pipeline Repair and Maint enance
I nst allat ion of Hot -Tapped Connect ions
PLI DCO Weld + Ends Couplings
PLI DCO Split Sleeves
Use of PLI DCO Smit h Pipeline Repair Clamps
20
306
308
309
310
311
312
313
314
Page 93 of 111
SAEPSAEPSAEPSAEP-
315
316
317
318
SAEP- 319
SAEP- 321
SAEP- 323
SAEP- 324
SAEP- 325
SAEP- 1131
SAEPSAEPSAEPSAEPSAEPSAEPSAEPSAEPSAEPSAEP-
1132
1133
1135
1140
1141
1142
1143
1144
1145
1150
00-SAI P-06
01-SAI P-02
02-SAI P-01
32-SAI P-11
I nst allat ion of St opple Fit t ings
Per f or mance Qualif icat ion of Coat ing Per sonnel
Test ing and I nspect ion (T & I ) of Shell & Tube Heat Exchanger s
Pr essur e Relief Valve Pr ogr am Aut hor izat ion f or
I nst allat ion, Delet ion and Changes
Pr essur e Relief Valves- Rout ine Test , I nspect ion,
Q ualit y Assur ance and Regulat ion
Per f or mance Q ualif icat ion Test ing and Cer t if icat ion of
Saudi Ar amco Welder s
Per f or mance Qualif icat ion Test ing of Cont r act
Welder s and Br azing
Cer t if icat ion Review and Regist r at ion of Pr oj ect Welder s and
Br azer s
I nspect ion Requir ement s f or Pr essur ized Equipment
Pr essur e Relief Valve Pr ogr am Use of For m 3099A,
RV Aut hor izat ion
I nst r uct ions f or Using t he Relief Valve St and
For m 3750, Pr essur ing Relieving Device Valve Test St and
On-St r eam I nspect ion Administ r at ion
Qualif icat ion and Cer t if icat ion of Saudi Ar amco NDT Per sonnel
I ndust r ial Radiat ion Saf et y
Q ualif icat ion of Saudi Ar amco NDT Per sonnel
Radiogr aphic Examinat ion
Magnet ic Par t icle Examinat ion
Liquid Penet r ant Examinat ion
I nspect ion Cover age on Pr oj ect s
Pr essur e Test Requir ement s
Ret ir ement Thickness of I n-Plant Piping
I nspect ion of Posit ive Seal Coupling Syst ems
I nspect ion of Air -Cooled Heat Exchanger s
Page 94 of 111
NGL
PIPELINE DEPT.
B31.8( 1)
WELLHEAD PIPING
SSD Fence
B31.4( 2)
B31.8(1)(4)(5)
B31.4( 3)
DF=0.72
OFF-PLOT
DF=0.5(2)
DF=0.5
ZV
SWD WELL
Water
B31.3(1)
ON-PLOT
RECEIVER
LAUNCHER
B31.3(1)
B31.4( 2)
FLARE STACK
zv
B31.3( 1)
Flare Gas
B31.3(1)(5)
Gas
Oil
Condensate
B31.4(1)
zv
PIPELINE DEPT.
PROD. HDR.
ZV
B31.3
B31.4,
DF=0.5
GAS
B31.3(5)
B31.3(1)
Wasia Well
WATER+GAS
SPECTACLE PLATE
UER Well
B31.8(2)
DF=0.5
B31.3
FLOWLINE
ON-PLOT
OFF-PLOT(1)
B31.8(3)
DF=0.72(2)
FLOWLINE
WELLHEAD PIPING
Note: Water line to EWT, Sewer line to
pit, and Instrument air lines are
designed as per B31.3.
B31.8(3)
DF=0.5( Class 1-3)
=0.4( Class 4 )
DF=0.72
OFF-PLOT
ON-PLOT
PLOT LIMIT VALVE
Page 95 of 111
WELLHEAD
Page 96 of 111
Page 97 of 111
SUPPORTS
13.0
Suppor t s
Saudi Ar amco Engineer ing Encyclopedia out lines t he f unct ion and design of
dif f er ent t ypes of suppor t s used f or :
•
Tanks
•
Vessels
•
Piping
Ref er t o sect ions MEX 10107 and 110.03 f or backgr ound inf or mat ion.
Figur e 1 shows dif f er ent t ypes of suppor t s such as Rigid Suppor t s,
Rest r aint s, St ops and Guides. Figur e 2 depict s Flexible or Resilient
Suppor t s. Figur e 3 shows anchor s inclusive of concr et e anchor s.
Table 1 is a guide t o commonly r ef er enced dr awings wit hin Saudi Ar amco
r elat ing t o suppor t s and r ef er ence should always be made t o t he lat est
r evision. Typical dr awings ar e at t ached.
Page 98 of 111
Table 1
Index
Plant No
Drawing No
Sheet No
Revision No
Description
L/M
990
AD-036990
2
0
Metricated saddle details for large diameter unrestrained pipelines.
L
990
AD-036990
1
13
Saddle details for large diameter unrestrained pipelines.
L/M
990
AB-036774
1
7
Pipe ring girder details
S
990
AB-036453
1
2
Wellhead pipe supports and anchor at wellhead
L
990
AB-036555
1
7
Standard wear pads for unrestrained pipelines
L
990
AB-036530
1
8
Offset & portable pipe supports for unrestrained pipelines 16” and
L
990
AB-036100
1
8
Ring girders for bolting to supports for 16” O.D through 32” O.D
L
990
AB-036207
1
10
Pipe spacings (attached)
L
990
AD-036697
2
0
Metricated standard maximum spans for above ground
L
990
AC-036697
1
2
Maximum spans for above ground unrestrained pipelines 14” and
L/M
990
AE-036252
1
4
Corrosion bar wear support
smaller. (attached)
Pipe.
unrestrained pipelines 14” and larger using wear pads or saddles.
larger using wear plates or saddles.
RIGID SUPPORTS
SHOE
SADDLE
BASE ADJUSTABLE
SUPPORT
DUMMY SUPPORT
TRUNNION
RESTRAINTS/GUIDES
BOX-IN GUIDE
SLEEVE GUIDE
VESSEL
CHANNEL GUIDE
STOP WITH SHOE
VERTICAL BOX-IN GUIDE
FLEXIBLE OR RESILIENT SUPPORTS
PIPE HANGER
SUSPENDED FROM SIDE
OF STRUCTURE
SLING TYPE PIPE
HANGER
PIPE SUPPORT BEAM
SUSPENDED BY RODS
LOAD AND
DEFLECTION
SCALE
VARIABLE LOAD SUPPORT
SMALL CHANGE IN EFFECTIVE LEVER ARM
LARGE CHANGE
IN EFFECTIVE
LEVER ARM
CONSTANT LOAD SUPPORT
RELATIVE
CONSTANT LOAD
Page 101 of 111
ANCHORS
ANCHOR
ANCHOR
BEARING SURFACE
BEARING
SURFACE
TYPICAL THRUST BLOCK FOR 90
DEGREE BEND OR ELBOW
TYPICAL THRUST BLOCK FOR 45
DEGREE BEND OR ELBOW
TYPICAL THRUST BLOCK FOR
TEE CONNECTION
BEARING
SURFACE
TYPICAL THRUST BLOCK FOR
END CAP
TYPICAL THRUST BLOCK FOR
REDUCER
Page 102 of 111
NON-DESTRUCTIVE
EXAMINATION
14.0
Non Dest r uct ive Examinat ion
Nondest ruct ive Test ing
Saudi Ar amco Engineer ing Encyclopedia out lines t he basics of t he var ious
met hods and should be consult ed f or backgr ound inf or mat ion. A number of
Saudi Ar amco Engineer ing Pr ocedur es (SAEP) exist cont r olling t he
per f or mance of nondest r uct ive t est ing (NDT). Non-dest r uct ive Examinat ion
(NDE) and Non-dest r uct ive Evaluat ion (NDE) ar e ot her f r equent ly used
t er ms dependent on count r y and cont ext .
Common abbr eviat ions used f or NDT met hods ar e P.T (Penet r ant Test ing),
MT (Magnet ic Par t icle Test ing), RT (Radiogr aphic Test ing), U.T (Ult r asonic
Test ing), ET (Elect r omagnet ic Test ing), V.T (Visual Test ing), AET (Acoust ic
Emission Test ing), L.T (Leak Test ing), NRT (Neut r on Radiogr aphic Test ing),
I RT (I nf r a-Red Test ing) and can be f ur t her sub-divided int o sub-met hods
such as WFMT (Wet Fluor escent Magnet ic Par t icle Test ing)
Cur r ent SAEP’s include:
•
•
•
SAEP 1143 Radiogr aphic Test ing
SAEP 1144 Magnet ic Par t icle Test ing
SAEP 1145 Penet r ant Test ing
The list ed SAEP’s out line how t he par t icular met hod is t o be applied wit hin
Saudi Ar amco and out lines all necessar y st eps t o per f or m t he t est and
r epor t t he t est r esult . Table 1 out lines t he Accept ance Cr it er ia f or t he
applicable SAEP’s and t he Saudi Ar amco f or m t o be used. Figur e 5 pr ovides
guidance on how t o int er pr et and evaluat e r adiogr aphs.
Page 103 of 111
NDT
Met hod
VT
PT
MT
RT
SAEP
Fut ur e
1145
1144
1143
Table 1
Accept ance Crit eria
Ref er Code
Figur e 1
Figur e 3
Post ed in RT Viewing Room (Fig
5)
FORM
Fut ur e
Figur e 2
Figur e 4
Figur e 6
Cur r ent ly no SAEP’s exist f or t he per f or mance of neit her UT nor ot her
Non-dest r uct ive t est ing t hat ar e consider ed “advanced”.
Dist inct ion needs t o be made bet ween manuf act ur ing f laws (i.e. lack of
f usion, et c) and I n-Ser vice det er ior at ion (i.e. Caust ic cr acking). For t he
det ect ion of manuf act ur ing def ect s t he t ype of NDT t o be per f or med, and
t he ext ent , is cont r olled by t he applicable const r uct ion code. Cur r ent ly, f or
det ect ion of in-ser vice det er ior at ion mor e lat it ude is available f or t he
ext ent and t ype of NDT t o be per f or med. Flaws induced f r om ser vice
nor mally init iat e at manuf act ur ing f laws.
I n-Ser vice Det er ior at ion nor mally manif ast s in t hr ee basic f or ms:
•
Cracking (sulf ide cracks, amine cracking, et c)
•
Met al loss due t o corrosion/ erosion
•
Change in Mat erial Propert ies (embrit t lement , et c)
No one NDT met hod is capable of det ect ing all t ypes of f laws and
select ion of an appropriat e NDT met hod f or t he specif ic f ailure
mechanism is paramount . Assist ance should be sought f rom t he
appropriat e Saudi Aramco specialist in t he Dhahran NDT Unit .
Page 104 of 111
FI GURE 1- PT Accept ance Crit eria
Liquid Penet rant Test ing Accept ance Crit eria
Code
Rej ect ion Crit eria
API 1104
1. Linear I ndicat ions
I ndicat ions > 1/ 16" (1.6mm) shall be consider ed as r elevant .
Relevant indicat ions ar e r ej ect able if :
Evaluat ed as cr at er cr acks or st ar cr acks and >5/ 32" (4mm) in
lengt h.
Evaluat ed as cr acks ot her t han cr at er cr acks or st ar cr acks.
Evaluat ed as I F and >1" (25.4mm) in t ot al lengt h in a cont inuous
12" (305mm) weld or >8% of t he weld lengt h.
2. Rounded I ndicat ions.
For evaluat ion, t he maximum dimension of r ounded indicat ions
shall be consider ed. I ndicat ions ar e r ej ect able def ect s if :
I ndividual indicat ion >1/ 8" (3.2mm) or 25% of t he t hickness of
t he t hinner member , whichever is less.
Dist r ibut ions of scat t er ed r ounded indicat ions exceed t he
concent r at ion of API 1104, Figur es 18 or 19.
Clust er ed r ounded indicat ions >1/ 2" (12.7mm) ar e pr esent .
Combined lengt h of clust er ed indicat ions > 1/ 2" in any 12"
(305mm) of weld.
Any individual indicat ion in a clust er >1/ 16" (1.6mm).
ANSI / A
SME
B31.1
&
ANSI / A
SME
B31.3
I ndicat ions > 1/ 16" (1.6 mm) shall be consider ed as r elevant
1. Linear I ndicat ion: Any Cr ack or linear indicat ion
2. Rounded I ndicat ions
I ndicat ions wit h dimensions > 3/ 16" (4.8mm)
Four or mor e r ounded indicat ion in a line separ at ed by 1/ 16"
(1.6mm) or less edge t o edge.
Ten or mor e r ounded indicat ion in any 6 sq. in. (3870mm2 ) of
sur f ace wit h t he maj or dimension of t his ar ea not t o exceed 6 in.
(150mm).
Page 105 of 111
ASME
Sect ion
VI I I ,
Div 1
I ndicat ions > 1/ 16" (1.6 mm) shall be consider ed as r elevant
The f ollowing I ndicat ions shall be r ej ect able:
1. Relevant linear indicat ion > 1/ 16" (1.6mm)
2. Relevant r ounded indicat ions > 3/ 16" (4.8mm)
3. Four or mor e r ounded indicat ions in a line separ at ed by 1/ 16"
(1.6mm) or less (edge t o edge).
AWS
D1.1
An Accept ance/ Rej ect ion cr it er ion is dependent on ser vice
condit ion. Ref er t o t he r elevant pr oj ect engineer or t he
I nspect ion Depar t ment .
Page 106 of 111
Figure 2 PT Form
Liquid Penetrant Examination Request & Report Form
Log No.
B.I. No.
J.O. No.
Location/Kilometer Reference
Technician
Level
Plant Name
Unit
Penetrant Mfg
White Light Intensity
Material Type
Penetrant Batch No.
UV Light Intensity
Contractor
Requested by:
Code / Acceptance Criteria
Liquid Penetrant System:
A-1____A-2____A-3____
B-1____B-2____B-3____
Surface Temperature
Plant No.
Aramco Rep.
Phone:
Material Form
Penetrant P/N
UV Light Model No.
Remover P/N.
UV Meter
Model No.
Date:
Sch. / Thickness
Developer P/N.
Material Form
Surface Condition / Part Description
Item
No.
Drawing No.
Equipment P/N
Line Reference.
Weld
No.
Welder
Symbol
Exam Results
ACC
Interpretation by: (print)
________________________________________
PT Level II / PT Level III
Badge No.
REPAIR
LOCATION
REJ
Signature:
NOTES:
1.
2.
All blanks are to be filled in or marked N/A (not applicable).
Examination performed by Level I require a sign-off by Level II or Level III.
Page 107 of 111
DEFECT
TYPE & SIZE
Date:
Figure 3 – MT Accept ance Crit eria
1
ANSI / ASME B31.1 Power Piping
The f ollowing r elevant indicat ions ar e unaccept able:
2
1.1
Any cr acks or linear indicat ions.
1.2
Rounded indicat ions wit h dimensions gr eat er
t han 3/ 16 inch (4.8mm).
1.3
Four or mor e r ounded indicat ions in a line
separ at ed by 1/ 16 inch (1.6 mm) or less edge t o
edge.
1.4
Ten or mor e r ounded indicat ions in any 6 squar e
inches (3870 mm² ) of sur f ace wit h t he maj or
dimension of t his ar ea not t o exceed 6 inches
(150 mm) wit h t he ar ea t aken in t he most
unf avor able locat ion r elat ive t o t he indicat ions
being evaluat ed.
ASME B31.3 - Chemical Plant and Ref iner y Piping
Any cr acks or linear indicat ions ar e unaccept able.
3
ASME Sect ion VI I I , Division 1
3.1
I ndicat ions wit h any maj or dimension gr eat er
t han 1/ 16 inch (1.6 mm) shall be consider ed
r elevant . All sur f aces t o be examined shall be
f r ee of :
3.2
Relevant linear indicat ions
3.2.1
Relevant r ounded indicat ions
gr eat er t han 3/ 16 inch (4.8 mm).
Page 108 of 111
3.2.2
4
Four or mor e r ounded def ect s in a
line separ at ed by 1/ 16 inch (1.6
mm) or less (edge t o edge) except
wher e t he specif icat ion f or t he
mat er ial est ablishes dif f er ent
r equir ement s f or accept ance so f ar
as def ect s ar e concer ned.
API 1104 - Welding of Pipelines and Relat ed Facilit ies
Any indicat ion wit h a dimension gr eat er t han 1/ 16 inch
(1.6 mm) shall be consider ed r elevant . Relevant
indicat ions shall be unaccept able when any of t he
f ollowing condit ions exist :
4.1
Linear indicat ions evaluat ed as cr at er cr acks or
st ar cr acks, which exceed 5/ 32 inch (3.96 mm)
in lengt h.
4.2
Linear indicat ions evaluat ed as cr acks ot her
t han cr at er cr acks or st ar cr acks.
4.3
Linear indicat ions evaluat ed as incomplet e
f usion (I F) and exceed 1 inch (25.4 mm) in t ot al
lengt h in a cont inuous 12-inch (304.8 mm) lengt h
of weld or 8% of t he weld lengt h.
4.4
I ndividual or scat t er ed por osit y (P) shall be
unaccept able when any of t he f ollowing
condit ions exist s:
4.5
The size of an individual por e exceeds 1/ 8 inch
(3.17 mm) or 25% of t he t hinner of t he nominal
wall t hickness j oined.
4.6
Clust er por osit y (CP) in any pass except t he
f inish pass shall be unaccept able when any of
t he f ollowing condit ions exist :
Page 109 of 111
4.7
An individual por e wit hin a clust er exceeds 1/ 16
inch (1.6 mm).
4.8
The CP diamet er exceeds 1/ 2 inch (12.7 mm).
4.9
The aggr egat e lengt h of CP in a cont inuous 12inch (304.8 mm) lengt h of weld exceeds 1/ 2
inch (12.7 mm).
Page 110 of 111
BASIC GUIDE TO EVALUATING AND INTERPRETING RADIOGRAPHS
S
C
A
L
E
SAEP-1143
RADIOGRAPHIC
EXAMINATION
(30-SEP-98)
C
C
SAEP-1141
INDUSTRIAL
RADIATION
SAFETY
O
R
R
O
S
I
O
O
D
E
N
DEALING WITH THE CORRECT RADIOGRAPH?
RT REPORT ACCOMPANIES RADIOGRAPH?
FORM 4719-A-ENG (9/98) USED?
VIEWING FACILITIES ACCEPTABLE?
SUBDUED BACKGROUND LIGHTING?
RADIOGRAPHIC VIEWER WITH SUFFICIENT LIGHT
OUTPUT VIA VARIABLE LIGHT SOURCE? (ISO 5580-85)
NO INTERFERING LIGHT FROM OUTER EDGES OF
FILM?
CALIBRATED DENSITOMETERS AS PER ASTM SE1079?
DENSITOMETER CHECKED AGAINST CALIBRATED
DENSITY STRIP PRIOR TO USE?
Oct 5th, 1998
JO or BI Number?
Component, Vessel or Piping Identification?
Seam or Weld Identification?
R1 for Repair (if applicable)?
Cutouts NW1 (if applicable)?
Date of Radiography?
Weld Thickness?
Pipe Diameter and Thickness?
Material Type?
Maps of Location Markers (if applicable)?
Film Brand and Designation?
No of Films per Cassette?
Single or Double Wall Exposure?
Single of Double Wall Viewing?
No of Exposures?
Isotope used or Max X-Ray voltage used?
Effective Focal Spot Sizes
Minimum Source to Film Distance?
Welder Symbol?
Defect Types?
Acc/Rej?
Technician Name, Badge # & Signature?
Technician Certified and to Level ?
RTFI Name, Badge #, Signature, Certified &
Level?
Check no artifacts, fogging, etc in area of
interest.
REVIEW RT REPORT
Check for Excessive Backscatter ( light image
of "B" on dark background rejectable).
Check if "F" is next to IQI (If applicable- it
signifies it has been placed Film side).
Check Geometric Unsharpness (Ug).
CHECK QUALITY OF
RADIOGRAPH
Check IQI WIre Identification, placement,
amount, material type, no damage, and required
wire is visible.
Check Density adjacent to required wire on IQI.
Check Density Variation -15% to +30%.
View Area of Interest.
Identify Relevant Flaws, Slag, Cracks, etc.
Size Relevant Flaws, diameter, length, width,
location, seperation distances, isolated, etc.
INTERPRET RADIOGRAPH
Compare Flaw Type with Relevant Code Edition
and Accept/ Reject.
Compare Flaw dimensions with Relevant Code
Edition and Accept/ Reject.
Final acceptance of radiograph by SA Certified
RTFI.
EVALUATE RADIOGRAPH
TO ACCEPTANCE CRITERIA
(APPENDIX I OF SAEP-1143)
Document Results, Date, Sign, Badge Number,
Level.
Communicate & Distribute Results, File Results
and store Film.
REPORTING
Page 111 of 111
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Wednesday, September 15,
Hot Tap.xls
Monday, June 12,
Sheet.xls
Tuesday, December 07,
in Lieu of Hydrotest.xls
Wednesday, September 15,
Saturday, July 10,
External Inspection.xls
Saturday, July 10,
Inspection.xls
Monday, June 05,
Saturday, July 10,
Inspection.xls
Tuesday, April 18,
Report.xls
Monday, January 22,
Wednesday, September 15,
Form.xls
Saturday, July 10,
Report.xls
Wednesday, September 15,
Inspection.xls
Saturday, July 10,
Schedules.xls
Wednesday, September 15,
Wednesday, September 15,
Sunday, December 12,
Saturday, July 10,
Saturday, July 10,
Priority.xls
Monday, June 12,
Saturday, July 10,
Drawing.xls
Monday, June 12,
Recommendations.xls
Wednesday, September 15,
Saturday, June 30,
Saturday, June 30,
Wednesday, September 15,
Data.xls
1999 10:09 AM
25600 INSP-9000 Engineering Inspection
2000
7:11 AM
16384 INSP-9001 Daily Planning
1999
1:17 PM
35328 INSP-9002 Request for 100% X-Ray
1999 10:12 AM
1999 6:31 PM
39424 INSP-9003 Battery Data Record.xls
13824 INSP-9004 Unfired Pressure Vessel
1999
13824 INSP-9005 Tank-In Service
6:32 PM
2000 11:01 AM
1999 6:43 PM
21504 INSP-9006 Leak Repair Report.xls
13824 INSP-9007 Tank Out-of-Service
2000
38400 INSP-9008 Pressure Test
3:11 PM
2001 1:12 PM
1999 10:18 AM
46592 INSP-9008_Form_(Template).doc
44032 INSP-9009 Radiographic Request
1999
58880 INSP-9010 Weld Inspection
7:01 PM
1999 12:49 PM
40960 INSP-9011 Ultrasonic Testing
1999
13824 INSP-9012 Equipment Inspection
7:09 PM
1999 12:59 PM
1999 1:00 PM
1999 7:26 AM
1999 7:28 PM
1999 7:31 PM
37888
20480
133120
54272
56832
INSP-9013
INSP-9014
INSP-9016
INSP-9017
INSP-9018
Frequent Inspection.xls
Vessel Inspection.xls
Landing Base.xls
Ultrasonic Request.xls
Off-Plot Piping Repair
2000
1999
8:50 AM
8:01 PM
18432 INSP-9020 Design Job Request.xls
75776 INSP-9021 Blank Isometric
2000
8:50 AM
30720 INSP-9022 Thickness Survey &
1999
2001
2001
1999
1:05
8:19
8:16
1:07
40448
53248
65536
37376
PM
AM
AM
PM
INSP-9024 Coating Survey.xls
INSP-9025-1 RV audit1.doc
INSP-9025-2 RV audit2.doc
INSP-9027 Pipeline Hydrotest
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Tuesday, December 07, 1999 1:30 PM
Procedures-Liquid Penetrant Exam..xls
Wednesday, September 15, 1999 1:10 PM
Procedures-Magnetic Particle Exam..xls
Tuesday, December 07, 1999 1:31 PM
Inspection Summary.xls
Wednesday, September 15, 1999 1:12 PM
Inspection Status.xls
Wednesday, September 15, 1999 1:13 PM
Inspection Report-Multimapping.xls
Wednesday, September 15, 1999 9:05 AM
Hydrotest Interval.xls
Saturday, April 15, 2000 7:43 AM
Wednesday, September 15, 1999 1:14 PM
Record Sheet.xls
Monday, May 17, 1999 10:07 AM
External Inspection.doc
Tuesday, June 25, 2002 4:02 PM
External Inspection.doc
Wednesday, January 10, 2001 11:25 AM
Existing.dot
38912 INSP-9030 Aramco Inspection
44032 INSP-9031 Aramco Inspection
38400 INSP-9033 Vessel Internal
37376 INSP-9034 Vessel Daily T&I
76288 INSP-9035 Ultrasonic Testing
40960 INSP-9036 Change of Revalidation
25088 INSP-9037 Scraper Run Report.doc
35328 INSP-9038 Coating Environment
26624 INSP-9039 Pressure Relief Valves
511488 INSP-9039A Pressure Relief Valves
270336 INSP-9039B PRV Ext Insp
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