Piping QC Course of Aramco & SABIC Part-2

This article is about Piping QC Course of Part-2 of Aramco, SABIC and other International oil and gas companies. Course series is developed for Engineers, Supervisors and QC professionals based on international standards and codes.

What is SIS?

The Safety Instruction Sheet would typically contain information regarding safety procedures, installation guidelines, operating instructions, and other relevant details to ensure the safe and proper functioning of the piping system. It is an important document that helps ensure compliance with safety standards and guidelines during the installation, operation, and maintenance of the piping system.

2. Why we perform hardness & impact test?

The hardness test is performed to measure the hardness of a material, which is an important property that indicates its resistance to deformation, indentation, or scratching. By measuring the hardness, you can assess the material’s mechanical properties, such as its strength, toughness, and ability to withstand wear or indentation.

The impact test, on the other hand, is used to evaluate the material’s behavior under high deformation rates or sudden loading conditions. It measures the material’s ability to absorb energy and withstand sudden impacts or shocks. The impact test provides information about the material’s toughness and its resistance to brittle fracture.

3. What is Sour and Non Sour Service?

“Sour Service” refers to environments or applications where the presence of hydrogen sulfide (H2S) is expected or encountered. Hydrogen sulfide is a highly corrosive and toxic gas that can be present in reservoir fluids, well fluids, and production systems. Sour service conditions require special considerations in material selection and design to ensure the integrity and safety of equipment and pipelines.

On the other hand, “Non-Sour Service” refers to environments or applications where hydrogen sulfide is not present or is not expected to be encountered. In non-sour service conditions, the risk of hydrogen sulfide corrosion and its associated hazards is not a concern, allowing for the use of standard materials and equipment that may not have the same level of resistance to corrosion or other challenges posed by sour environments.

4. What do you know about Water quality Analysis?

Water quality analysis involves the assessment of various parameters and characteristics of water to determine its suitability for specific purposes. Some of the common parameters analyzed in water quality analysis include pH, chloride content, dissolved oxygen, turbidity, total dissolved solids (TDS), conductivity, and various chemical and biological contaminants.

In the context you mentioned, the pH value and chloride content are being specifically monitored for their impact on the corrosion behavior of materials in contact with water. The pH value indicates the acidity or alkalinity of the water, and it can affect the corrosion rate of certain materials. The specified pH ranges for carbon steel (CS) and stainless steel (SS) provide guidelines for maintaining an environment that minimizes corrosion.

Chloride content is another important factor in water analysis as it can contribute to the corrosion of certain metals, particularly stainless steel. The specified chloride limits for CS and SS help ensure that the water does not contain excessive chloride concentrations that could accelerate corrosion.

For CS the PH Value is 7.5 ±5 and chloride < 250 ppm. For SS the PH value is 10.5±5 & chloride < 50 ppm.

5. What is punch list?

A punch list, also known as a deficiency list, is a document that identifies items or tasks that are incomplete, damaged, or not in accordance with the specified requirements in a construction project or any other type of project. It serves as a checklist to ensure that all outstanding issues are addressed and resolved before a specific milestone or project completion.

The punch list typically includes items that need to be rectified or completed before certain stages or events, as you mentioned:

Punch list items to be done before hydro test: These are tasks or deficiencies that need to be addressed before conducting the hydrostatic pressure testing of the system. This ensures that the system is in a suitable condition for testing and minimizes the risk of any major issues during the test.
Punch list items to be done before mechanical completion (MC): These are items that should be completed before the project reaches the stage of mechanical completion. This includes tasks such as finalizing installations, conducting necessary tests, and ensuring that all components are properly installed and functioning.
Punch list items to be done after MC but before commissioning: These are tasks or deficiencies that need to be resolved after the mechanical completion but before the commissioning stage of the project. This ensures that all systems and equipment are fully operational and meet the required standards before they are put into service.
Punch list items to be done before plant acceptance: These are outstanding items or issues that need to be resolved before the final acceptance of the entire plant or facility. This could include any remaining tasks, adjustments, or corrections required for the project to meet the specified requirements and standards.

6. What Is reinstatement?

Reinstatement refers to the process of inspecting and restoring completed construction activities or systems before they are handed over for pre-commissioning or final acceptance. It involves verifying that all construction works have been properly completed, all necessary tests and inspections have been conducted, and any defects or deficiencies have been rectified.

During the reinstatement phase, the responsible parties, such as the construction team or quality control personnel, conduct a thorough inspection of the completed construction activities. This inspection ensures that the work meets the required specifications, standards, and applicable codes.

The reinstatement process may involve various activities, including:

Visual inspection: Checking for any visible defects, damages, or incomplete work.
Functional testing: Verifying the proper functioning of systems, equipment, or components, such as valves, pumps, electrical systems, etc.
Documentation review: Ensuring that all necessary documentation, including test reports, inspection records, as-built drawings, and certificates, are complete and accurate.
Compliance check: Verifying that the construction activities comply with the approved design, applicable regulations, and contractual requirements.
Deficiency rectification: Addressing any identified deficiencies or non-conformities by taking corrective actions and ensuring that they are resolved before handover.

7. Name the SATIP & SAES of Piping and what is the Codes?

The SATIP (Saudi Aramco Typical Inspection Plans) and SAES (Saudi Aramco Engineering Standards) related to piping are as follows:

SATIP:

SATIP-A-004-01: Pneumatic Pressure Testing
SATIP-A-004-02: Hydrostatic Testing of On-Plot Piping
SATIP-A-004-03: Hydrostatic Testing of Pipelines
SATIP-A-004-05: Leak Testing (Per SAES-A-004)
SATIP-L-350-01: On-Plot Metallic Piping Installation (Excluding Brazed Piping)
SATIP-L-108-01: Valve Inspection, Testing & Installation

SAES:

SAES-A-004: General Requirements for Pressure Testing.
SAES-A-007: Hydrostatic Testing Fluids and Lay-Up Procedures.
SAES-L-100: Applicable Codes and Standards for Pressure Piping Systems.
SAES-L-105: Piping Material Specifications.
SAES-L-108: Selection of Valves.
SAES-L-109: Selection of Flanges, Stud Bolts and Gaskets.
SAES-L-110: Limitations on Pipe Joints and Components.
SAES-L-150: Pressure testing of Plant Piping & Pipelines.
SAES-L-310: Design of Plant Piping.
SAES-L-350: Construction of Plant Piping.
SAES-L-450: Construction of On-Land and Near-Shore Pipelines.

These standards and procedures provide guidance and requirements for various aspects of piping design, construction, testing, and inspection in Saudi Aramco projects. They ensure compliance with industry best practices, codes, and regulations, and help maintain the quality, safety, and reliability of piping systems.

8. What is the ASTM code for the following?

A. Pipes:- I. Carbon Steel II. Alloy Steel III. Stainless Steel IV. Nickel Steel.
B. Tubes: – I. Carbon Steel II. Alloy Steel III. Stainless Steel IV. Nickel Steel.
C. Wrought Iron Fittings: – I. Carbon Steel II. Alloy Steel III. Stainless Steel IV. Nickel Steel.
D. Forged Fittings: – I. Carbon Steel II. Alloy Steel III. Stainless Steel IV. Nickel Steel.
E. Cast Fittings: – I. Carbon Steel II. Alloy Steel III. Stainless Steel IV. Nickel Steel.
F. Plates: – I. Carbon Steel II. Alloy Steel III. Stainless Steel IV. Nickel Steel.

Ans:

The ASTM codes for the following materials are as follows:

A. Pipes: I. Carbon Steel: ASTM A53 Gr. A/B, ASTM A106 Gr. A/B/C, ASTM A333 Gr.1/Gr.6 II. Alloy Steel: ASTM A335 Gr.P1/P2/P5/P7/P9/P11/P12/P22 III. Stainless Steel: ASTM A312 TP304/TP304L/TP304H/TP308/TP310/TP316/TP316L/TP316H/TP317/TP321/TP321H/TP347/TP347H/TP348/TP348H IV. Nickel Steel: ASTM A333 Gr.3/Gr.8

B. Tubes: I. Carbon Steel: ASTM A53 Gr. A/B, ASTM A106 Gr. A/B/C, ASTM A333 Gr.1/Gr.6 II. Alloy Steel: ASTM A335 Gr.P1/P2/P5/P7/P9/P11/P12/P22 III. Stainless Steel: ASTM A269 TP304/TP304L/TP304H/TP316/TP316L/TP316H/TP317/TP321/TP347/TP347H IV. Nickel Steel: ASTM B161/B165/B167/B407/B444/B523

C. Wrought Iron Fittings: I. Carbon Steel: ASTM A234 WPB/WPC/WP11/WP22/WP5/WP9/WP91 II. Alloy Steel: ASTM A234 WP1/WP5/WP9/WP11/WP22/WP91 III. Stainless Steel: ASTM A403 WP304/TP304L/TP316/TP316L/TP321/TP321H/TP347/TP347H/TP317 IV. Nickel Steel: ASTM B366 N04400/N06600/N06625/N08800/N08825/N10276

D. Forged Fittings: I. Carbon Steel: ASTM A105/A105N II. Alloy Steel: ASTM A182 F1/F5/F9/F11/F22/F91 III. Stainless Steel: ASTM A182 F304/F304L/F316/F316L/F321/F347 IV. Nickel Steel: ASTM B564 N04400/N06600/N06625/N08800/N08825/N10276

E. Cast Fittings: I. Carbon Steel: ASTM A216 WCB/WCC II. Alloy Steel: ASTM A217 WC1/WC6/WC9/C5/C12 III. Stainless Steel: ASTM A351 CF8/CF8M/CF3/CF3M/CG8M/CG3M/CK20 IV. Nickel Steel: ASTM A494 CW-6MC/CY-40/CZ-100/CY-5SnBiM

F. Plates: I. Carbon Steel: ASTM A36/A283/A516 II. Alloy Steel: ASTM A387 Gr.2/Gr.5/Gr.9/Gr.11/Gr.12/Gr.22/Gr.91 III. Stainless Steel: ASTM A240 TP304/TP304L/TP316/TP316L/TP321/TP347/TP310/TP310S IV. Nickel Steel: ASTM B168 N04400/N06600/N06625/N08800/N08825/N10276

9. What are levels of inspection explain?

The levels of inspection are as follows:

Level 0: This level requires documentation only, and no vendor inspection is required. It means that the inspection is based on reviewing the provided documentation, such as certificates, reports, and records.

Level 1: At this level, only the final inspection is required prior to shipping. The inspection focuses on verifying that the product or equipment meets the required specifications and quality standards before it is sent out for delivery.

Level II: This level includes a pre-inspection meeting to discuss the inspection requirements and expectations. It also involves one or more unspecified in-progress surveillance visits to ensure that the work is progressing according to the approved plans and procedures. All witness and hold points, which are critical stages or activities, are inspected. Finally, a final inspection is conducted to ensure that the product or equipment is ready for shipment.

Level III: Similar to Level II, Level III includes a pre-inspection meeting, all witness and hold points, and a final inspection. However, in addition to these activities, regular in-progress surveillance is conducted on a daily, weekly, or biweekly basis. This level of inspection provides more frequent monitoring of the work to ensure compliance with the required standards.

Level IV: At this level, a resident inspector is continuously present at the worksite, monitoring the work throughout the entire project. The resident inspector provides real-time oversight and verification of the work being carried out, ensuring adherence to the specified requirements and quality standards.

10. What are types of Layup Inspection?

Layup inspections refer to the inspection activities conducted during the process of laying up a system or equipment for temporary shutdown or preservation. The types of layup inspections are as follows:

Dry Lay-Up: In this type of layup, the system or equipment is completely drained of any fluids and dried out. It involves removing all water, chemicals, or other substances from the system to prevent corrosion or deterioration during the shutdown period. Inspections during dry lay-up may include visual inspections, moisture checks, and corrosion monitoring.
Wet Lay-Up: Wet lay-up involves filling the system or equipment with a preservative fluid or solution to protect it from corrosion during the shutdown period. The preservative fluid is selected based on the specific requirements of the system and its compatibility with the materials. Inspections during wet lay-up may include checks for fluid level, chemical concentration, and corrosion inhibitor effectiveness.
Ambient Lay-Up: In ambient lay-up, the system or equipment is shut down without any specific preservation measures. It relies on ambient conditions, such as temperature and humidity, to provide some level of protection against corrosion. Inspections during ambient lay-up may focus on monitoring environmental conditions and conducting periodic visual inspections for signs of corrosion or deterioration.
Inert Gas Lay-Up: In this type of layup, the system or equipment is filled with an inert gas, such as nitrogen, to displace oxygen and create an oxygen-free environment. This helps prevent corrosion and degradation of the internal surfaces. Inspections during inert gas lay-up may include monitoring the gas pressure, conducting gas purity checks, and inspecting the integrity of the gas sealing system.

Piping QC Course of Aramco & SABIC Part-2