PEW-405.01 Inspect New Piping

8/13/2019 PEW-405.01 Inspect New Piping

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Saudi AramcoInspection Department

Training & Contractor Workforce Saudization Group

INSPECT NEW PIPING

PEW-405.01

The training materials contained in this module are the property of the Saudi Arabian Oil Company (Saudi Aramco) andare intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses Anymaterial contained in this manual !hich is not already in the public domain" may not be copied" reproduced" sold" given ordisclosed to third parties or other!ise used" in !hole or in part" for purposes other than for use in Saudi Aramco#s$rofessional %ngineering Development &nit courses !ithout the prior !ritten permission of the Chief %ngineer of Saudi

Aramco


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PEW-405.01 PARTICIPANT REVISIONS

DATE REVISIONDESCRIPTION PAGES! A""ECTED

'*+*, CO-$.%T%/%0ISIO1 A..S& 2AS3A" S CA0%" - A44AD

i


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PEW-405.01 PARTICIPANT TABLEOFCONTENTS

#OD$%ECO#PONENT PAGE

O25%CTI0%S'

Terminal Ob6ective'

%nabling Ob6ectives'

I1T/OD&CTIO1

I1S$%CT $I$%S ,

1ominal $ipe Si7e,

$ipe 8all Thic9ness,

$ipe -anufacturing $rocesses:

Seamless $ipe:

%lectric /esistance;8elded $ipe (%/8):

Submerged Arc;8elded $ipe+

Spiral;8elded $ipe+


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Cleaning'

%nd $reparation '

$ositive -aterial Identification

$reheating

$ost !eld;heat treatment :

2utt;8elds=

Soc9et 8elds@*

='

I1S$%CT I1S&.ATIO1=

Insulation Components=

Insulation=

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5ac9et =+

Adhesives and Sealants =?

Accessories =

Insulation types?*

3ot Insulation systems?'

Cold Insulation systems types?'

I1S$%CT C/OSS;CO&1T/B $I$%.I1%S?@

Components?@

&ses ?,

&nderground $ipelines ?,

Aboveground $ipelines?+Submarine $ipelines ?

%%/CIS% ' I1S$%CT $I$I1> *

%%/CIS% I1S$%CT $I$% S

%%/CIS% @ I1S$%CT $I$% 5OI1TS :

%%/CIS% , %D 5OI1TS" >AS4%TS ST&D 2O.TS?

%%/CIS% : I1S$%CT $I$% S&$$O/TS /%ST/AI1TS'*'

%%/CIS% + I1S$%CT I1S&.ATIO1'*,

%%/CIS% = I1S$%CT C/OSS CO&1T/B $I$I1> A$$.ICA2.% COD%S STA1DA/DS'*+

>.OSSA/B'*?

ADD%1D&- 2 D%TAI. O< 3%A0B 8%.DI1> 2OSS''=

ADD%1D&- C I1S&.ATIO1 I1S$%CTIO1 C3%C4.IST'*

iv


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PEW-405.01 PARTICIPANT OBJECTIVES

O'ECTIVES

Ter(ina) O*+ecti,e

&pon completion of this module" the $articipant !ill be able to inspect ne! plant pipingusing the appropriate references" tools" and eEuipment" and according to applicableSaudi Aramco and industry standards

Ena*)ing O*+ecti,e-

In order to accomplish the Terminal Ob6ective" the $articipant !ill be able toF

$erform inspection on ne! plant piping

$erform inspection on ne! cross;country pipelines

Note: This training material has been developed using the latest available versions of appliable

!audi "ramo and industr# standards. $o%ever& these douments are regularl# updated.Therefore& it is the responsibilit# of the 'nspetor to ensure that he is onduting his

inspetions aording to the latest& updated version of these douments.

'


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PEW-405.01 PARTICIPANT INFORMATION

INTROD$CTION

$iping systems are li9e arteries and veins in the oil industry $iping systems comprise ofpipes" flanges" bolting" gas9ets" valves etc They also include pipe hangers" supportingelements and other items necessary to prevent over pressuri7ation and overstressing ofthe pressure containing components 3ence" one can say that pipe section !hen fitted!ith valves and other mechanical eEuipment and properly supported by hangers andsupports are called piping

The function of piping systems is to safely contain and convey fluids from one location toanother The follo!ing are general types of piping systems used for Saudi Aramcopro6ectsF

$lant piping

Cross;country pipelines

$lant piping is used !ithin the boundaries of a process plant" such as a petroleumrefinery or chemical plant $lant piping transports liEuids or gases from one item of planteEuipment to another" or bet!een plots !ithin one plant area $lant eEuipment consistsof items such as compressors" furnaces" heat exchangers" pressure vessels" pumps"and storage tan9s

Cross;country pipelines are used outside the boundaries of process plants They

convey liEuid petroleum" petroleum products" liEuid;gas mixtures" or natural gasDepending on the application" these pipelines connect plants or facilities such as!ellheads" >OS$s" $umping or compressing facilities" Oil termination and shippingfacilities" /efineries and chemical plants" Temporary storage facilities" >as treating" >asmetering and regulation" >as mains" >as service to end users

The $iping Inspector shall be 9no!ledgeable on all aspects and components of a pipingsystem including the follo!ingF

$ipes


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INSPECT PIPES

$ipe is a pressure;tight cylinder used to convey a fluid or to transmit a fluid pressure andconforms to the dimensional reEuirements ofF

AS-% 2@+'*- 8elded and Seamless 8rought Steel $ipe

AS-% 2@+'- Stainless Steel $ipe

The Inspector verifies that the pipe conforms to the pro6ect specification and designdra!ings The follo!ing five items should be verified for the pipeF

1ominal pipe si7e (1$S)

$ipe !all thic9ness (Schedule number)

-ethod of fabrication

$ipe -aterial

$iping Class

No(ina) Pipe Size

1ominal pipe si7e (1$S) is a dimensionless designator of pipe si7e It indicates standardpipe si7e !hen follo!ed by the specific si7e designation number !ithout an inch symbol


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$ipe !all thic9ness is expressed by the term schedule The inspector chec9s theschedule number" such as :" :S" '*" '*S" *" *S" @*" @*S" ,*" ,*S" +*" ?*" ?*S" '**"'*" ',*" '+*

A schedule number indicates the approximate value of the expression '*** $S" !here$ is the service pressure and S is the allo!able stress" both expressed in pounds persEuare inch ($SI) The higher the schedule number" the thic9er the pipe is The suffix GSHis added to schedule number to differentiate bet!een stainless steel from carbon steel

Pipe #anufacturing Proce--e-

A description of pipe should include the manufacturing process 8hen the engineer isselecting material" the pipe manufacturing process !ill help him determine the potential

overall Euality of the pipe

The $iping Inspector verifies that the pipe is manufactured using one of the follo!ing fiveprocessesF

Seamless pipe

%lectric resistance;!elded pipe (%/8)

Submerged arc;!elded pipe

Spiral;!elded pipe


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SA%S;.;'@+ prohibits the use of %/8 pipe for ha7ardous service for plant piping %/8pipe is acceptable for pipelines

Su*(erged Arc/We)ded Pipe

The submerged arc;!elding process is the most common for manufacturing carbon steelpipe %lectric resistance;!elded pipe and submerged arc;!elded pipe are high;Eualitypipes that are suitable for most services -ost cross;country pipelines consist of one ofthese t!o types of pipe Since they contain a longitudinal seam" ho!ever" they may notbe as high a Euality as seamless pipe The 6oint Euality factor for these t!o processes isusually ta9en bet!een *? and'*" depending on the piping design code" the materialspecification" and the degree of inspection

Spira)/We)ded Pipe

Spiral;!elded pipe is used primarily for cross;country pipeline services" !here thespecifications and !eld details that are used result in a 6oint Euality factor of *=: to '*$er SA%S;.;'@+" for plant piping conforming to AS-% 2@'@ and at permanentlymanned facilities" spiral;!elded pipe shall not be used in sour gas service unless it isstress relief heat treated in a furnace at '':*< for one hour Spiral;!elded pipe may beused for sour liEuid lines

"urnace/We)ded Pipe


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INSPECT PIPE "ITTINGS

$ipe fittings are used extensively in process plants as !ell as other piping systems Theyserve the overall process in many aspects" such asF

Change the flo! direction

2ring t!o or more pipes together

Divert a single flo! into t!o branching flo!s or more

Alter the pipe diameter

Tap the process for temperature or pressure readings

Terminate a pipe

There are several !ays or techniEues for connecting a fitting to a pipe


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The follo!ing table summari7es the pipe schedule that corresponds to each fittingpressure class for rating purposesF

Rating of T.readed and Socket We)d "itting-

The Inspector shall also be able to differentiate bet!een the standard types of fittings"such as (See also


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"igure 01 #o-t Co((on T2pe- of "itting-

'*


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E)*o3-

%lbo!s are used to change the direction of a pipe run Standard elbo!s change thedirection by either ,: or * .ong;radius elbo!s have a bend radius of ';' times thenominal pipe si7e" and short;radius elbo!s have a bend radius eEual to the nominal pipesi7e The long;radius elbo! is more commonly used Short;radius elbo!s are normallyonly used if there is a space restriction for the piping system layout


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Tees and crosses are mostly used in plant utility piping" such as instrument air or1itrogen lines Tees are designed !ith extra thic9ness in the area !here the branchconnects !ith the run The extra thic9ness provides reinforcement to compensate for the

strength reduction that is caused by the hole cut in the run The Inspector should verifythat no street tees (!ith male threads) are used per SA%S;.;'*:

"igure 51 Variou- T2pe- of Tee- and Cro--e-

Reducer-

/educers change the diameter in a straight section of pipe" and are either of theconcentric or eccentric type (See


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"igure 61

Socket Set Reducer-

%atera)-

.aterals are special types of tees as sho!n in


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"igure 91 T.readed and Socket/We)ded Coup)ing-

Pipe Cap- and P)ug-

As sho!n in


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"igure :1 Cap- and P)ug-

Integra))2 Reinforced ranc. Connection-

A !elding outlet fitting" or integrally reinforced branch connection" sho!n in


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/egion @F /educing tee or branch !eld !ith reinforcing pad or full encirclementsleeve

/egion ,F 8eldolet or branch !eld !ith reinforcing pad

/egion :F 8eldolet" soc9olet" threadolet" or !elding boss per SASD A%;*@+'=: andA%;*@++,@ (See Addendum 2)


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"igure


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INSPECT PIPE 'OINTS

As discussed earlier for pipe fitting connections" the Inspector should be 9no!ledgeableon the main pipe 6ointing methodsF

Threaded 5oints

8elded 5oints


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maximum on special items such as fire hydrants unless a larger si7e is approved by theassigned Chairman" $iping Standards Committee for the specific applicationF

Sea) 3e)ding

AS-% 2@'@ defines seal !elding as a !eld intended primarily to provide 6oint tightnessagainst lea9age in metallic piping In Saudi Aramco" seal !elding is reEuired forthreaded 6oints in flammable and toxic services per SA%S;.;''*

8here seal !elding is reEuired" the seal !eld shall be a fillet !eld going from the outerdiameter of the female part" and it should be smooth !ith slight concavity as allo!ed by

AS-% 2@'" to the male part covering all exposed threads !ithout undercut TheInspector should chec9 that no $T


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Threaded 6oints" do!nstream of a seal !elded root valve" !hich discharge

directly to an open drainage system or to the atmosphere

%xtended body valves !ith integrally reinforced !elding end per A$I STD +*

T.read Engage(ent

A minimum thread engagement must be maintained to insure integrity of the threadedconnection and to preclude possibility of lea9age The minimum length of the engagedthreads pipe shall meet the reEuirements of AS-% 2'*' for taper pipe thread Theminimum number of engaged pipe threads shall meet the reEuirements of the follo!ingtable

T.read Engage(ent Re?uire(ent- for Taper Pipe T.read-

No(1 Pipe SizeNu(*er of

T.read- Engaged

'J @,J +

'J through ';'J =

J through @J ?

,J '*

We)ded 'oint-

8elding is one of the primary !ays of 6oining pipe 8elded 6oints represent the ultimatein safety and reliability

As discussed in $%8;,* (8elding Inspection I)" !elding should be carried out using aEualified procedure and !elders Included in the standard procedure are base;metalspecifications" electrode" 6oint preparation" !eld position" !elding process" techniEues"electrical details" preheat and interpass temperatures" and post;!eld heat treatmentreEuirements

The Inspector should follo! the same seEuence for pre;!elding and !elding inspectionas detailed in $%8;,* and $%8;,*@" respectively Specific information related to pre;!elding and !elding inspection for piping 6oints !ill be briefly discussed in this module"such asF

$reparation for !elding

Cleaning

*


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5oint preparation

$ositive -aterial Identification

$re;heating

$ost !eld heat treatment

In addition" this module !ill briefly discuss the standard reEuirements" including AS-%2@'" for the three types of !elding 6oints ie butt;!elded" soc9et" and fillet 6oints

Preparation for We)ding

2efore any !elding is done" the specific details of ho! it !ill be carried out" ie the

!elding procedure must be specified and demonstrated to achieve acceptable results%ach of the AS-%A1SI 2@' Codes" plus modifications contained in SA%S;8;*'' orSA%S;8;*' as applicable" specify !elding procedure Eualification reEuirements

8elding procedure Eualification demonstrates that the approach specified for doing the!eld !ill achieve acceptable results !hen properly applied

The next step is to Eualify the particular !elders and !elding eEuipment to carry out thespecific !elding procedure 3ere again" the relevant AS-%A1SI 2@' Code plus Saudi

Aramco reEuirements must be met SA%$;@, specifies ho! to register certified !elderand provide 5CC

The result of these t!o steps is that both the !elding procedure" and the individuals andeEuipment executing it" have been confirmed to produce acceptable results

C)eaning

Internal and external surface to be thermally cut or !elded shall be clean and free frompaint" oil" rust" scale" or other material that !ould be detrimental to either the !eld orbase metal !hen heat is applied If such items are not cleaned" they could mix !ith the!eld metal at elevated temperatures and result in poor Euality !elds

End Preparation

The ends of the components to be !elded must be set to the correct geometric shapesuitable for the materials" !all thic9ness" and !elding process involved 5oint designshall comply !ith the follo!ingF

8hen !all thic9ness ratio of 6oined pipes is less than or eEual to ':" 6oint design

details shall comply !ith the respective AS-% 2@' design code

'


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8hen !all thic9ness ratio of 6oined pipes is greater than ':" end preparations

and geometry shall comply !ith AS-% 2'+: J2utt 8elding %ndsJ /efer to


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and stated by procedure Eualification The follo!ing identifies specific benefits ofpreheatingF

Dries the metal and removes surface moisture" !hich" if present" !ould result inporosity of the !eld metal

/educes the temperature difference bet!een the base metal and the !eld to

reduce the cooling rate of the !eldment" lo!ers the !eld hardness to reduceresidual stresses" and reduces coolingshrin9age stresses

3elps maintain the !eld pool molten for a longer time to permit maximum fluxing

and separation of impurities

3elps drive off absorbed gases (such as hydrogen) !hich could contribute to

!eld porosity

The Inspector should revie! specific preheat temperature reEuirements as specified inAS-%A1SI 2@' Codes based on the base metal ($ or S numbers)" !eld metal (Anumber) and !all thic9ness that are being 6oined (See


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"igure 001 Pre/.eat te(perature- AS#E 5015!

,


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Po-t 3e)d/.eat treat(ent

$ost !eld heat treatment ($83T) is used to avert or relieve the detrimental effects ofhigh temperature and severe temperature gradients that are inherent in !elding" and torelieve residual stresses that are created by bending and forming

The follo!ing summari7es the principal reasons for $83TF

Stress relief is the most common reason for specifying $83T" and is the only

consideration for the reEuirements that are specified in the AS-%A1SI 2@'Codes /esidual stresses !ill remain in the pipe and result from shrin9age as the!eld and ad6acent pipe metal cool do!n from elevated !elding temperatures/esidual stresses !ill also remain after bending or forming processes

If these residual stresses are too high" they can lead to premature failure of the

pipe AS-%A1SI 2@' Code reEuirements specify !hen $83T is reEuired torelieve these residual stresses and bring the pipe to an initial stress;free state$83T is also reEuired to reduce fabrication stresses to minimi7e the potential forstress;corrosion crac9ing in certain process environments" such as caustic"amines" and !et 3S

After !elding the normal grades of stainless steels (ie" those that are not

stabili7ed !ith alloy additions)" it is necessary to heat;treat the material to restoremaximum corrosion resistance

$83T is reEuired to prevent caustic embrittlement of !elded carbon steel pipethat handles al9aline solutions Caustic embrittlement is a form of stresscorrosion !here the residual stresses due to !elding are sufficient to causefailure

$83T is sometimes necessary to reduce !eld hardness in certain materials

-inimi7ing !eld hardness reduces the tendency to crac9" especially in certainprocess environments such as caustic or !et 3S

Specific heat treatment temperature and procedure reEuirements are specified in theappropriate AS-%A1SI 2@' codes based on the pipe material and !all thic9ness being

6oined (See


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+


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"igure 041 Re?uire(ent- for Po-t 3e)d .eat treat(ent AS#E 5015!

utt/We)d-

2utt;!elds are made bet!een t!o components !hose edges are in close proximity2utt;!elded 6oints in piping systems are primarily of the single;0 configuration and are!elded from the pipe outside surface .arger diameter pipes" !hich can be accessedfrom the inside !ill often be !elded from both sides using a double;0 type of 6ointpreparation

The 6oint preparation and the procedure that is used ensure that there is complete fusionbet!een the edges of the components being 6oined 5oint designs per AS-% 2@'@ or2@', sho!n in


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8here necessary" !eld metal may be deposited inside or outside the component topermit alignment or provide for machining to ensure satisfactory seating of rings orinserts

2utt;!elds !ill al!ays be used to !eld pipe ends together" to !eld butt;!eld;typeflanges or fittings to pipe ends" or to !eld the edges of formed plate together !hen plateis used to manufacture pipe

"igure 051 Accepta*)e utt/We)ded 'oint De-ign for E?ua) Wa)) T.ickne--AS#E 5016!

?


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"igure 061 Accepta*)e utt/We)ded 'oint De-ign for $ne?ua) Wa))T.ickne-- AS#E 5016!


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"igure 071 T2pica) *acking ring- and con-u(a*)e in-ert- AS#E 5015!

Socket We)d-

A soc9et;!elded;type fitting attachment is designed !ith a recess in its end to permit thepipe to be inserted The Inspector should confirm that the pipe is !ithdra!napproximately ': mm (''+in) from the bottom of the recess The gap is needed inorder to provide space to permit differential thermal expansion" !hich occurs during!elding and normal operation %xperience has sho!n that !ithout this gap the potentialto develop crac9s in the fillet !eld is very high due to !eld contraction

It should be noted that this gap should be provided prior to !elding only 1evertheless" if

the Inspector notes that the gap has closed after the completion of !elding and nocrac9s have developedK then there should be no !orries The axial gap shall bemaximum of @ mm and minimum of ': mm as per


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"igure 091 #ini(u( 3e)ding di(en-ion- for -ocket 3e)ding co(ponent-AS#E 5015!

Similar to threaded 6oints" the Inspector should verify that the maximum si7e of soc9et;!elded 6oints in ha7ardous services is 'N inches for ne! construction (SA%S;.;''*)The Inspector should allo! for a maximum 6oint si7e of inches in ha7ardous service formaintenance" minor field modifications of existing piping systems" and !hen necessaryto match existing eEuipment connections


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"igure 0:1 Size of fi))et 3e)d AS#E 5015!

In piping systems" fillet !elds are only used for slip;on flanges (


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T!o flanges

A gas9et to provide a seal bet!een the flanges

2olting to 9eep the assembly together

"igure 0


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Stud bolts and nuts

5ac9scre!s


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"igure 4=1 T.readed f)ange-

Socket/We)ded ")ange-

A soc9et P !elded flange has an oversi7ed bore that is partially machined into the endopposite the face (See


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"igure 441 )ind f)ange-1

S)ip @ on ")ange-

A slip P on flange has an oversi7ed bore It is slipped over the pipe outside diameter andpro6ects slightly beyond the pipe end (See


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"igure 461 %apped f)ange-

We)ding @ Neck ")ange-

A !elding P nec9 flange is the strongest of the standard flange attachment types Theend of the flange is butt !elded to the end of the pipe The flange bore is si7ed to matchthe pipe bore (See


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flange contact !ith the gas9et over a large surface" and limits local flange bending that iscaused by bolt load

A flat face is typically used only for cast or ductile iron flanges" !ith relatively lo!;strength material" or !hen a steel flange must mate to such a flange -inimi7ation offlange bending is necessary for cast iron" ductile iron" or other relatively lo! strengthmaterials" but not for steel flanges Therefore" there are fe! applications for flat;faceflanges in refinery or petrochemical services because there are relatively fe!applications !here such lo!;strength flange materials are acceptable

Sheet;type gas9ets that extend from the flange inside diameter to the outside diameter(ie" full face) typically are used !ith flat;face flanges The Inspector should confirm thata flat;faced flange !ith a full;face gas9et is used !hen one or both of the mating flangesare cast iron" aluminum" plastic" or any other material that could be over stressed by thebolt load (SA%S;.;'*) In addition" flat;face flanges are used for highly corrosive

service !here contact of fluid !ith flange facing must be avoided

"igure 491 ")at faced f)ange

Rai-ed/"ace ")ange-

The area !here the gas9et is located is higher than the surrounding flange surface"typically by ': mm (''+ in) This raised;face portion of the flange has a speciallymachined" serrated finish that is suitable for the typical gas9et types used in processplant applications (See


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the raised face since this !ill result in possible 6oint lea9age The Inspector should alsoverify that the face is free of dirt

A raised;face flange is used for a very broad range of services" and is the most commontype used in Saudi Aramco plants

"igure 4:1 Rai-ed/faced f)ange

Ring/'oint ")ange-

A ring;6oint flange face consists of a groove that is machined into the flange end (See


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Ga-ket- and Ga-ket T2pe-

The gas9et provides the seal in a flange assembly The Inspector must be familiar !ith

the four general gas9et types that are typically used in pipe flanges for process plant andpipeline applicationsF

Spiral !ound gas9ets

Solid metal ring gas9ets

Sheet gas9ets

Insulating gas9ets ($i9ote9)

The Inspector must verify that the gas9et type" rating" and dimension per pro6ect

specification and service conditions 3e chec9s for damage particularly in the seatingelement

Spira)/Wound Ga-ket-

A spiral;!ound gas9et is manufactured by alternately !inding strips of metal and softfiller material around a mandrel (See


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"igure 4


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/ing;6oint gas9ets are typically softer than the flange grooves Therefore" the gas9et"rather than the groove" !ill deform slightly under the applied bolt load A variety of ringmaterials are available to suit the particular service needs The most common materials

are iron or soft steel" ,;+L chrome" and stainless steels A solid metal ring;type gas9etis used only !ith ring;6oint;type flanges

The Inspector should be familiar !ith SA%S;.;'* selection reEuirements for ring;6ointgas9et" as follo!sF

The soft iron" octagonal ring;6oint gas9ets shall be used !ith AS-% 2'+:" -SS;

S$;,," or Saudi Aramco standard ring 6oint flanges


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"igure 501 S.eet t2pe ga-ket-

Another non;asbestos sheet;gas9et material is composed of flexible graphite The higherEuality flexible graphite sheet gas9ets employ a stainless steel sheet insert !ith theflexible graphite for increased strength This gas9et material has exhibited excellentcorrosion resistance in most process plant applications" and has provided goodperformance at elevated temperatures

Sheet gas9ets may be used !ith flat or raised;face flanges The Inspector should befamiliar !ith SA%S;.;'* selection reEuirements for sheet gas9ets" as follo!sF

Compressed synthetic fiber sheet gas9ets !ith an oil resistant binder" '+ mm

(**+@ in) thic9" may be used for Class ':* flanges in non;ha7ardous servicesup to @*C (,:*


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-aterials for sour services shall be as follo!sF

Standard Euenched and tempered AST- A'@ >rade 2= stud bolts !ith 3 nuts

shall be used for sour !et services !hen the bolting is (a) not directly exposed tohydrogen sulfide" (b) not buried or insulated" (c) not eEuipped !ith flangeprotectors" or not deprived of direct atmospheric exposure AST- A@* >rade.= stud bolts !ith >rade , or = nuts can be used under the same conditions

Stud bolts conforming to AST- A'@ grade 2=- !ith nuts to A', >rade 3-

shall be used under conditions of (a) direct exposure to sour environments or!hen the bolting !ill be (b) buried or insulated" or (c) eEuipped !ith flangeprotectors" or other!ise deprived of direct atmospheric exposure AST- A@*>rade .=- bolts and >rade =- nuts can be used under the same conditions

Steel machine bolts conforming to AST- A@*= >rade 2 may be used on flat;

faced cast;iron or non;metallic flanges in non;sour environmentK nuts shallconform to AST- A:+@ >rade D This boltnut combination may be used in sourservices !hen the >rade D nuts are not resulfuri7ed" and the flange materialsare deemed suitable by the -aterials %ngineering &nit of -%CCD in CSDSuch bolting may be 7inc coated or preferably 7inc;aluminum (>alvalum) coated


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Ta*)e/SAEP/570/=0 @ "riction "actor- for Different %u*ricant-

%u*ricant- "riction "actor-Tor?ue

Correction "actor-oly >raphite *+ *+=

Tool 5oint Compound *? *?

>raphite and Oil(used as the base line for torEue

values in Table;SA%$;@:';*)'* '*

Aerocote Q, '' ''

4O$/;4OT% '' ''

%.;$/O C:A '' ''


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c) /otation of flanges" measured as the offset bet!een elevations of boltholes on opposite sides of a flange centerline" shall not exceed M , mm

d) The tilt of a flange measured at the periphery across any diameter shallnot exceed '+ mm from the sEuare position


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measuring the applied load shall be used (ie" torEue !rench or stud tensioner) In this!ay" there is greater assurance that uniform bolt load is achieved


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Ta*)e/SAEP/570/=4 @ Tor?ue Va)ue for A0


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Ta*)e/SAEP/570/=5 @ Tor?ue Va)ue- for I-o)ating Ga-ket- PIBOTEB!on AS#E 0917 and AS#E 0916: Serie- A & C)a-- 07= t.roug. C)a-- 47== ")ange-

Stud o)t Size

inc.Tor?ue #ini(u(

"t/%*N @*

:? +*

'**

=? '+*

' ,:

';'? @::

';', :**

';@? +?*

';' ?**';:? ''**

';@, ':**

';=? ***

**

;', @'?*

;' ,,**

NoteF TorEue values based on @*"*** psi tension load and *':


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Dirt2 or Da(aged ")ange "ace-

Dirt" scale" scratches" protrusions" or !eld spatter on

gas9et seating surfaces provide lea9age paths or cancause uneven gas9et compression that results in lea9age

E>ce--i,e %oad- in t.e Piping S2-te( at ")ange %ocation-

%xcessive piping system forces and moments at flangescan distort them and cause lea9s Common causes of thisare inadeEuate flexibility" using excessive force to alignflanges" and improper location of supports or restraints

T.er(a) S.ock /apid temperature fluctuations can cause flanges todeform temporarily" resulting in lea9age

I(proper Ga-ket Size or #ateria)

&sing the !rong gas9et si7e or material can result inlea9age

I(proper ")ange "acing A rougher flange;surface finish than specified for spiral;!ound gas9ets can result in lea9age

Note: The prinipal methods for orreting flange lea/age problems are be#ond thesope of this ourse. $o%ever& several of them are easil# orreted based onthe auses of lea/age.

Safet2 of ")anged 'oint- A--e(*)2

Though it seems flanged 6oint assembly is very straightfor!ard and simple"petrochemical industries have experienced tragic incidents due to failures of flanged

6oints The main reEuirements and factors to achieve reliable flanged 6oints are thefollo!ingF

ood !or9manship by the people assembling the flanges

Careful inspection during the above stages as reEuired

:@


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>enerally" the flange has very high safety margins in its design Over the years ofexperience" it has been found that the human factor is the main reason for failures in theflanged 6oints There are standards and acceptable practices that should be carefully

follo!ed to insure safety around the flanged 6oints

Improper surface finish of the flange facing

>as9et is not centered

&neven bolting torEue

TorEue value are either under minimum reEuired or !ay over to the point that

gas9et is completely not functional

Installing the !rong gas9et" type or rating

:,


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INSPECT VA%VES

0alves are ma6or components of a piping system and reEuire careful attention during thedesign process Selecting a valve is based upon the reEuired valve functionF to bloc9flo!" throttle flo!" or prevent flo! reversal There are numerous types of valves Thevalve most commonly used (approximately =:L of the time) is the gate valve SA%S;.;**? provides special service limitations and selection reEuirements for valves

The *,;SA-SS;series of specifications provides additional valve design reEuirementsOnce a valve is selected" its flange rating class must be specified based on its designpressuretemperature and the -AO$ of the class


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INSPECT S$PPORTS AND RESTRAINTS

$ipe supports are used to support the !eight of the piping system and the contents ofthe system The supports 9eep the pipe elevated at a desired height above the groundThe specific number and locations for pipe supports are determined to ensure thefollo!ingF

The pipe stress that is caused by the !eight load must be 9ept !ithin allo!able

limits

The pipe must not sag excessively

/eaction loads at eEuipment connections must not be excessive

8hen practical" ne! piping should use existing supports to minimi7e costs As much aspossible" ne! piping should be located in existing pipe;!ays Intersecting pipe;!ays arelocated at different elevations to facilitate access and future piping installation StandardDra!ing AC;*@+*= specifies the minimum spacing of lines that are supported onsleepers or pipe rac9s

/estraints control or limit movement of the pipe in one or more directions Such restraintmay be reEuired to reduce thermal expansion reaction loads at eEuipment connections"or to limit pipe vibration Some restraints 9eep the pipe from moving vertically or laterallybut allo! the pipe to move longitudinally

Other restraints do not allo! the pipe to move in any direction A support is a speciali7edtype of restraint that prevents pipe movement under vertical !eight loading

Genera) Guide)ine-

$iping systems should be routed to facilitate their support and restraint" to minimi7e cost"and to limit additional structural and foundation reEuirements The follo!ing guidelinesshould be consideredF

The piping system should support itself to the extent possible to minimi7e theamount of additional structural steel that is reEuired to provide support

$iping !ith excessive flexibility may reEuire the addition of restraints to minimi7e

excessive movement andor vibration that may be caused by fluid flo!" !ind" orearthEua9e Therefore" piping systems should be designed !ith only the flexibilityneeded to accommodate the expected thermal movement !ithout causing

:=


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excessive pipe stresses or end point reaction loads Systems should not beoverly flexible

$iping that is prone to vibration" such as reciprocating compressor suction anddischarge systems" should be supported independently from other pipingsystems This independent support 9eeps the effects of the vibration;pronesystem confined to that system and directly associated structures The effectsare not transmitted to other systems

$iping that is located in structures should be routed beneath platforms and near

ma6or structural members" at points that permit added loading /outing beneathplatforms avoids access interference problems /outing near ma6or structuralmembers minimi7es the need to increase the si7e of structural members or toprovide additional local reinforcement" due to increased bending moment

8hen possible" piping should be routed near existing structural members tominimi7e the need for additional structure and foundations

The layout of the piping system must consider the safety of personnel !ho may

be near the pipe -a6or pieces of eEuipment" particularly heat exchangers"vessels" and tan9s" must be accessible for fire;fighting eEuipment $ipe;!aysmust be routed to provide this access There must be adeEuate space underpipe;!ays for people to !al9 and !or9


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Absorb other loads imposed on piping system to limit loads on connected

eEuipment

.imit pipe deflection

.imit resultant pipe stresses

Selection of a particular type of support or restraint depends on such factors as thefollo!ingF

8eight load

/estraint load

Clearance available for attachment to pipe

Availability of nearby existing structural steel

Direction of loads to be absorbed or movement to be restrained

Design temperature

Allo!ance reEuired for thermal movement of pipe

T2pe- of Support-

This section discusses and illustrates various types of supports and restraints for pipingsystems

The t!o general classes of supports are as follo!sF

/igid


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(including pipe support structure) This clearance is also reEuired for aboveground piping crossing !ith another pipe

+*


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Rigid Support-

/igid supports are the more common of the t!o support types %ngineers use rigidsupports !hen !eight support is needed and no provision to permit vertical thermalexpansion is reEuired A rigid support does the follo!ingF

Allo!s lateral movement and rotation

-ay or may not prevent movement up

$revents movement do!n


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"igure 5:1 a-e Ad+u-ta*)e Support

"igure 5;1 Du((2 Support

"igure 5


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$ipe hangers are also a form of rigid support $ipe hangers support the pipe fromstructural steel or other facilities that are located above the pipe and carry the pipe!eight load in tension A pipe hanger rod moves freely parallel and perpendicular to the

pipe axisK therefore" thermal expansion is not restricted longitudinally or laterally The roddoes restrict vertical thermal expansion The rod also must be long enough so that itdoes not restrict pipe lateral or longitudinal movement

SA%S;.;@:* discourages use of hanger rods and suggests that they be replaced !ithrigid pipe supports $er SA%S;.;@:*" the Inspector must confirm the follo!ing itemsrelated to rod hangersF

/od hangers are not used for lines 'J 1$S and larger in liEuid service or multi

phase flo!

All hangers are provided !ith means for vertical ad6ustment

Suitable loc9ing devices are used at all threaded connections of the hanger

assembly (double nuts)

/od hangers are sub6ected to tensile loading only

$racticality for replacing them !ith rigid pipe supports should be evaluated and

implemented" during construction


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"igure 601 Pipe 8anger Su-pended "ro( Side of Structure

"igure 641 Pipe Support ea( Su-pended 2 Rod-

")e>i*)e or Re-i)ient Support-


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/eEuired movement

Installation geometry

Standard models available

Varia*)e %oad ")e>i*)e Support

The variable load flexible support is the more common of the t!o types of flexiblesupport 8ith variable load supports" pipe movement stretches or compresses thespring" changing the load that the spring exerts on the pipe The spring is selected toprovide the correct amount of support load to the pipe throughout the movement rangei*)e Support

8ith constant load flexible supports" the load that is exerted by the support on the piperemains constant throughout the movement range The use of a variable;length internal;moment arm mechanism accomplishes this constant load This type of support isreEuired !hen the load variation caused by the vertical thermal movement in a variable;load;type spring is too large to be accommodated by the piping system" or !hen thethermal movement is greater than approximately @ in (=: mm)


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"igure 661 Con-tant %oad Support

T2pe- of Re-traint-

/estraints have the follo!ing t!o primary purposes in a piping systemF

They control the unrestricted thermal movement of the pipe by directing or

limiting it >enerally" a piping system is totally restrained at its end connections toeEuipment

They control" limit" or redirect the thermal movement to reduce the thermal stressin the pipe or the loads exerted due to thermal movement on eEuipmentconnections

They absorb loads imposed on the pipe by other conditions %xamples of these

other conditions are as follo!sF

8ind

%arthEua9e

Slug flo!

8ater hammer


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Direction of pipe movement to be restrained

.ocation of the restraint point

-agnitude of the load to be absorbed

One or more types of restraint or support may be combined at one location" dependingon the piping system design needs Three types of restraints are as follo!sF

Stops

>uides

Anchors

Stop-

Stops are restraints that limit the movement of the pipe in the longitudinal directionStops are designed to 9eep the pipe from moving axially beyond a point or from movingaxially at all


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$revent !ind;induced movement

Control thermal expansion


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"igure 6;1 o>/In Guide

"igure 6/In Guide on Side of Ve--e)

Anc.or-

Anchors stop pipe movement in all three translational directions %ngineers use anchorsto isolate one section of a piping system from another section in terms of loading anddeflection A total anchor that eliminates all translation and rotation at one location is notas common as one or more restraints that act at a single location It is difficult to designeffective rotational anchors or restraints $lant piping more commonly uses directionalanchors that restrain the pipes only in their translational directions


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"igure 7=1 Anc.or

"igure 701 Anc.or

"igure 741 Anc.or

=*


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INSPECT COATING

$ipelines shall be painted in accordance !ith SA%S;3;**" SA%S;3;'*' and SA%S;3;'** to give protection from corrosion This topic !ill be covered in separate trainingcourse

='


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INSPECT INS$%ATION

Insulation shall be provided on the piping systems as sho!n in $ IDs and other designdocuments Sections of the insulation shall be removable to allo! for on;streaminspection The follo!ing standards are applicable for inspecting insulationF

SA%S;1;**'F 2asic criteria" industrial insulation

SA%S;A;'*:F 1oise control

SA%S;2;**+F enerally the reasons for using insulation areF

Condensation prevention

/eduction of heat loss

$ersonnel protection

1oise reduction

In-u)ation Co(ponent-

In-u)ation

There are many different types of insulation materials available for both commercial andindustrial piping applications The insulation must be applied in a single layer !hen thetotal thic9ness does not exceed @H (=: mm) Other!ise" for thic9ness above @NH (*

=


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mm)" insulation shall be comprised of multiple layers (See


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Insulation up to ' in (@** mm) outside diameter (OD) shall be held in place

!ith '+ gauge Type @*, stainless steel tie !ire" except cellular glass andpolyisocyanurate foam insulation" !hich may be held in place !ith fiberglass

reinforced pressure;sensitive tape or stainless steel tie !ires applied over thetape

Insulation ' in (@** mm) OD to , in (+'* mm) OD shall be held in place

!ith ' in ('@ mm) !ide by *** in (*:' mm) thic9 Type @*, stainless steelbands and !ing seals Above , in (+'* mm) OD" use @, in (' mm) !ide by*** in (*:' mm) thic9 bands and !ing seals

"igure 751 Sc.e(atic of a piping in-u)ation -2-te(

=,


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81/129


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The Inspector shall verify that metal 6ac9eting ' in (@** mm) OD to , in (+'* mm)OD is held in place !ith ' in ('@ mm) !ide by *** in (*:' mm) thic9 Type @*,stainless steel bands and !ing seals

Above , in (+'* mm) OD" use @, in (' mm) !ide by *** in (*:' mm) thic9bands and !ing seals

"igure 771 Co(ponent of a piping in-u)ation

==


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"igure 791 I))u-tration of 'acketed In-u)ation

Ad.e-i,e- and Sea)ant-

Adhesives are used to bond the insulation either to itself or to the surface on !hich it isapplied %ach different type of insulation reEuires its o!n special type of adhesive

Sealants (Caul9ing) are used to seal an insulation system from the elements" therebyprotecting the underlying insulation from damage Insulation systems must be caul9ed

andor sealed at all possible points of moisture entry The Inspector shall verify that nofeatheredge of caul9 exists


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cloth membranes as !ell as metal mesh should be used to reinforce the !eather barrierapplication

The Inspector must chec9 that all adhesives and sealants are supplied in their factory;sealed containers Any adhesive or sealant" !hich is exposed to temperatures outsidethe recommended temperature ranges during storage" shall be removed from the siteand replaced !ith ne! material In addition" the Inspector must not allo! use of anymaterials !ith expired shelf life


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penetrate the vapor barrier In this case" the Contractor shall be reEuired to submit aproposed procedure for the use of scre!s for the $urchaser#s approval

"igure 7;1 E>a(p)e of acce--orie- needed for ,ertica) pipe in-u)ation

In-u)ation t2pe-

In Saudi Aramco" there are t!o types of insulation systems

3ot Insulation system

Cold Insulation system

?*


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8ot In-u)ation -2-te(-

The purpose for a hot insulation system is as follo!F

3eat conservation insulation

$rocess Stability Insulation

$ersonnel $rotection Insulation


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Insulation is not installed over nameplates" expansion 6oints" rotating 6oints and

other applications !here the intended use !ould be compromised


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$-e-

Cross;country pipelines transport liEuids" gases" or liEuid;gas mixtures bet!een thefacilities previously cited These pipelines provide a convenient method of transferringmaterial from one facility to another and from the source of crude oil or gas to the finaldelivery terminals or end;users This section discusses the follo!ing general types ofcross country pipelinesF

&nderground

Aboveground

Submarine

$nderground Pipe)ine-

The most common type of cross;country pipeline is buried underground A cross;countrypipeline is normally buried because it isF

&sually the least expensive form of construction

Safer than aboveground construction

&nderground pipelines are buried by digging a trench" leveling the trench bottom"installing appropriate bedding material to provide uniform support" placing the pipe in thetrench" and filling the trench bac9 in Sufficient cover must be used over the pipe torestrain the line and protect it from external loads

Note: *or more information& refer to 'nspet a/fill peration (odule

Additionally" consideration is al!ays given to the potential end movements of buriedpipelines If these movements exceed :* mm ( in)" a full thrust or drag anchor must beprovided A thrust anchor is designed for the full axial forces that are expected at the

location A drag anchor is not designed for the complete thrust load that is expected andpermits some movement of the pipe In this case" the drag anchor installation must limitthe end movement of the pipeline to a maximum of + mm (*: in)

Anchors are needed to limit movement at the ends of the pipeline" at changes indirection or si7e" and at above; to belo!;ground transition points %xcessive movementof a buried pipeline can cause shifting of the soil that supports the pipe" subsidence ofthe cover" or damage to the pipeRs external coating (if one is installed) In extreme cases"

?,


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excessive movement could cause pipe overstress" inadeEuate cover depth" or externalpipe corrosion

2uried concrete bloc9s act as drag anchors to underground pipelines These bloc9anchors must be si7ed to resist the applied loads considering the local terrain (forexample" soil or roc9 characteristics) and friction


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"igure 7


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Aboveground pipelines are cross;country pipelines that are constructed above thesurface of the ground Aboveground pipelines are used !hen a buried pipeline is notpractical The primary reasons for the use of aboveground pipelines include terrain

features" such as solid roc9" that ma9e underground piping expensive or impossible toconstruct It is not unusual to use sections of aboveground pipeline in an other!iseburied system to avoid local terrain features

Aboveground pipelines are supported by support structures and associated foundationssimilar to plant piping An aboveground pipeline !ith its associated supports andfoundations is usually more expensive than digging and filling trenches for anunderground pipeline Differential thermal expansion is a more significant design issuefor aboveground pipelines than for underground pipelines because of direct exposure tothe sun for aboveground pipelines

Aboveground pipelines may be either restrained or unrestrained A restrained pipeline

has anchors or restraints installed to restrict its thermal expansion movements and limitthe loads that are imposed on any above;to;belo!ground transition points Anunrestrained pipeline does not have anchors installed Therefore" the pipe istheoretically free to expand or contract due to changes in its metal temperature

-ost aboveground pipelines are designed as restrained systems" since the free thermalmovements can result in excessive loads being imposed on any above;to;belo!groundtransitions In extreme cases" this could eventually cause the pipe to move off itssupports The anchors that are used in restrained piping systems" and their associatedfoundations" must be designed for the anticipated loads that are caused by pipe thermalexpansioncontraction and friction Similar to buried pipelines" anchors are needed tolimit movement at the ends of the pipeline" at changes in direction or si7e" and at above;

to belo!;ground transition points

Aboveground pipe anchors typically employ local reinforcement at their attachment tothe pipe" such as sleeves and ring girders (See


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SIDE ELEVATION ELEVATION "A-A"

"igure 9=1 Ring girder SASD A/=59::6!

A

A20", 22", 24", 26", 30", 31", & 32" O.D.

PIPE TO BE SUPPORTED

$I$%/I1>>I/D%/

??


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Su*(arine Pipe)ine-

Submarine pipelines are cross;country pipelines that deliver oil or gas that is produced

offshore They are submerged in !ater" rest on the marine bottom" or are trenched andburied in the seabed To counteract buoyancy" submarine pipelines may be coated !ithconcrete

?


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PEW-405.01 PARTICIPANT EXERCISES

EFERCISE 01 INSPECT PIPING

' 8hich general types of piping systems are used !ithin Saudi Aramco

The $iping Inspector shall be 9no!ledgeable on !hich components of a pipingsystem

@ $ipe !all thic9ness is expressed by the term Schedule

a True UUUUUUUUUUU

b


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: 8hich Saudi Aramco standard prohibits the use of %/8 pipe for ha7ardousservice

+ 8hich type of pipe is generally the lo!est cost and the lo!est Euality

= Spiral !elded pipe is used primarily for !hich type of pipeline services

? 8hat is the 6oint Euality factor for seamless pipe

$ipe for plant applications shall be seamless or single P longitudinal seamsubmerged arc !elding and shall conform to !hich standards

'* The higher the schedule" the thic9er the pipe

a True UUUUUUUUU

b


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EFERCISE 41 INSPECT PIPE "ITTINGS

' $ipe fittings are used extensively is process plants as !ell as other pipingsystems" give three examples if their use

The reEuirement for plugs of the round headed type can be found in !hich SaudiAramco Standard

@ 8hich are the t!o primary design standards used for pipe fittings

, The Inspector shall be able to differentiate bet!een standard types of fittings"such as


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: >ive three examples of !hat the inspector must verify !hen inspecting elbo!s

+ 8hat is the purpose of a reducer

= >ive three examples of Tees

? >ive three techniEues for connecting a fitting to a pipe

@


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In !hat situation !ould !e use a lateral

'* 8hat are the reasons for using a pipe cap rather than a blind flange

,


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EFERCISE 51 INSPECT PIPE 'OINTS

' 8hich international standard defines seal !elding

8hat are the reasons for insuring thread engagement

@ 8hen the !all thic9ness ratio of pipes to be 6oined is less than or eEual to ':"6oint design details shall comply to !hich international code

, >ive three examples !hy pre;heat is used

:


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: >ive a reason or reasons !hy $ositive -aterial Identification is used in Saudi

Aramco

+ 1ame t!o types of !eld configurations

= 8hen inspecting a soc9et !eld type at !hat distance must the pipe be !ithdra!nand for !hat reasons

? 8hat type of material is $' according to AS-% 2 @'@

8hat is the number of threads that should be engaged on a ten inch pipe

+


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'* 8hen carrying out post !eld heat treatment !hat is the holding time for Carbon

Steel

'' Threaded 6oints should be avoided in !hich type of corrosion

' >ive four reasons for carrying out post !eld heat treatment

=


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EFERCISE 61 "%ANGED 'OINTS GASBETS & ST$D O%TS

'


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: 8hich is the strongest type of flange

+ 8hich type of flange is gas9et on the same elevation as the surrounding flangesurface

= >ive an example of three types of gas9ets

? 8hat Saudi Aramco Standard should be used for the selection of spiral !oundgas9ets

8hich type of gas9et material should be avoided !ith regard to health

'* 8hich is the most used type of insulation type of gas9et

'' 8hat type of stud bolts and nuts shall be used for sour !et services and is notexposed to 3ydrogen Sulfide


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' >ive three causes of flange lea9age

'**


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EFERCISE 71 INSPECT PIPE S$PPORTS & RESTRAINTS

' >uides are types of supports that limit the movement of the pipe >ive fourexamples of their typical applications

8hich dra!ing specifies the minimum spacing of lines that are supported onsleepers or pipe rac9s

@ A piping system needs supports and restraints >ive four reasons for this

, >ive three examples !hy !e use rigid supports

'*'


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: >ive t!o examples for the purpose of a restraint in a piping system

+ >uides are supports that limit the movement of the pipe >ive four examples of

typical application

= >ive an explanation !hy anchors are commonly used in plant piping

? 8hat is the most important consideration !hen for layout design of a pipingsystem

'*


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EFERCISE 91 INSPECT INS$%ATION

' >ive four examples for the use of insulation

8hat are !eather barriers used for

@ 8hat is the main use of adhesives

, >ive four examples for the purposes of hot insulation

: 8hat must the inspector chec9 regarding adhesives

'*,


110/129


+ In !hat forms do 6ac9ets come in

= 8hat shall happen to insulation that has become !et

? The insulation shall be applied in a single layer !hen the total thic9ness does notexceed

8hich Saudi Aramco Standard is used for noise control

'* The inspector must verify that all insulation used in Saudi Aramco pro6ects hasbeen tested for fire related values To !hat international standard

'*:


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EFERCISE :1 INSPECT CROSS CO$NTR PIPING &APP%ICA%E CODES & STANDARDS

' >ive three general types of cross;country piping

>ive t!o reasons !hy cross country piping is buried

@ 8hat could extreme movement of the pipe cause

, If pipe buried pipe movement is more than :*mm a full thrust or drag anchormust be used

True UUUUUUUU


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+ Concrete bloc9s can be used as an anchor

TrueUUUUUUUUUUUUUUU


113/129


114/129

PEW-405.01 PARTICIPANT GLOSSARY

i(perfection


115/129


environment of similar corrosivity and !hich is of similardesign conditions and construction material 8henestablishing the boundary of a particular piping circuit" the

Inspector may also si7e it to provide a practical pac9age forrecord9eeping and performing !eld inspection

piping engineer One or more persons or organi7ations acceptable to theo!ner;user !ho are 9no!ledgeable and experienced in theengineering disciplines associated !ith evaluatingmechanical and material characteristics !hich affect theintegrity and reliability of piping components and systemsThe piping engineer" by consulting !ith appropriatespecialists" should be regarded as a composite of allentities necessary to properly address a technicalreEuirement

piping -2-te( An assembly of interconnected piping" sub6ect to the sameset or sets of design conditions" used to convey" distribute"mix" separate" discharge" meter" control" or snub fluid flo!s$iping system also includes pipe;supporting elements" butdoes not include support structures" such as buildingframes" bents" and foundations

PW8T $ost !eld heat treatment

repair A repair is the !or9 necessary to restore a piping system toa condition suitable for safe operation at the design

conditions If any of the restorative changes result in achange of design temperature or pressure" thereEuirements for rerating also shall be satisfied Any!elding" cutting" or grinding operation on a pressure;containing piping component not specially considered analteration is considered a repair

rerating A change in either or both the design temperature or themaximum allo!able !or9ing pressure of a piping system Arerating may consist of an increase" decrease" or acombination Derating belo! original design conditions is ameans to provide increased corrosion allo!ance

-(a)) *ore piping SP) .ess than or eEual to 1$S

-oi)/to/air SA! interface An area in !hich external corrosion may occur on partiallyburied pipe The 7one of the corrosion !ill vary dependingon factors such as moisture" oxygen content of the soil" andthe operating temperature The 7one generally isconsidered to be from ' inches (@* cm) belo! to + inches

''*


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(': cm) above the soil surface $ipe running parallel !iththe soil surface that contacts the soil is included

-poo)- A section of piping encompassed by flanges or otherconnecting fittings" such as unions

te(per e(*ritt)e(ent A loss of ductility and notch toughness in susceptible lo!;alloy steels (eg" ' V Cr and V Cr) due to prolongedexposure to high temperature service (bet!een =**C to'*=*< (@=' to :== C))

t.ickne-- (ea-ure(ent )ocation- T#%-!

Designated areas on piping systems !here periodicinspections and thic9ness measurements are conducted

W"#T or W"#PT 8et fluorescent magnetic particle testing

'''


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PEW-405.01 PARTICIPANT ADDENDUMS

ADDEND$# A1 APP%ICA%E CODES AND STANDARDS

''


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APP%ICA%E CODES AND STANDARDS "OR PIPING SSTE#SAND T8EIR CO#PONENTS

Indu-tr2 Standard- for Piping S2-te(- and T.eir Co(ponent-

This section summari7es the scope of the follo!ing codes and standards that apply toSaudi Aramco piping systems and componentsF

A1SIAS-% codes

A1SIAS-% 2@'" Code for $ressure $iping

A1SIAS-% 2@'@" Chemical $lant and $etroleum /efinery $iping

A1SIAS-% 2@'," .iEuid Transportation Systems for 3ydrocarbons" .iEuid

$etroleum >as" Anhydrous Ammonia" and Alcohols

A1SIAS-% 2@'?" >as Transmission and Distribution $iping

A1SI and A$I standards and publications

ANSIAS#E 5015 C.e(ica) P)ant and Petro)eu( Refiner2Piping

A1SIAS-% 2@'@ establishes reEuirements for the safe design" construction"inspection" and testing of chemical plant and petroleum refinery piping This codeapplies to all piping !ithin the property limits of facilities that process or handle chemical"petroleum" or related products It applies to piping for all fluids" including the follo!ingF

>as" steam" air" and !ater


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Condensate

Crude oil .iEuid alcohol

.iEuid anhydrous ammonia

.iEuefied petroleum gas

.iEuid petroleum products

1atural gas liEuids

1atural gasoline

This code excludes systems that operate at or belo! '*@ 9$a (': psig)" belo! ;C (;*as transmission and distribution systems" including gas pipelines" gas

compressor stations" gas metering and regulation stations" gas mains" andservice lines up to the outlet of the customer#s meter set assembly

>as storage eEuipment of the closed;pipe type" fabricated or forged from the

pipe or fabricated from the pipe fittings" and gas storage lines

$ipe" valves" fittings" flanges" bolting" gas9ets" regulators" pressure vessels"

pulsation dampers" and relief valves

A1SIAS-% 2@'? excludes systems operating at or belo! ; C (;*


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Saudi Ara(co Standard- for Piping S2-te(- and T.eirCo(ponent-

The G. seriesH of the Saudi Aramco %ngineering Standards (SA%SRs) is the primarygroup of standards that specify additional Saudi Aramco engineering reEuirements forpiping systems that are !ithin the scope of the A1SIAS-% 2@' Codes These SA%SRsalso include other pressure piping services that are excluded from the Code TheSA-SSRs are primarily Gpurchase typeH documents that are included in the purchaseorder for an item to further specify its technical reEuirements They are not discussed inthis course" and the $articipants are referred to the Saudi Aramco -aterial SystemSpecifications -anual as reEuired for information The follo!ing material highlightsseveral of the SA%SRs that are relevant to piping system design

SAES/A/==6 Pre--ure Te-ting

SA%S;A;**, provides the general principles that apply to pressure testing of planteEuipment and plant piping This standard applies to ne!ly installed and existingeEuipment and piping The standard specifies that a pressure test be performed asfollo!sF

2efore the eEuipment or piping is placed into service

After repairs or alterations that affect the strength of the eEuipment

At scheduled intervals

8henever considered necessary or advisable by the responsible manager

This standard provides conditions" limits" and exceptions for pressure testing

SAES/A/==7 Safet2 In-truction S.eet

SA%S;A;**: outlines the procedure for preparing Safety Instruction Sheets (SISRs) forne! plants" for additions to existing plants" and for re;rating existing eEuipment SISRsprovide information in a consistent format on safe operating limits" protection devices"and special safety precautions This information is primarily used by operations"maintenance" and inspection personnel Critical plant piping and cross;country pipelinesmust have SISRs

SAES/8/==4 Interna) and E>terna) Coating- for Stee) Pipe)ine-and Piping

SA%S;3;** provides the mandatory internal and external coating selection andinstallation reEuirements for steel pipelines and piping" including the associated fittingsand appurtenances

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SAES/% -erie- Saudi Ara(co piping Standard-

SA%S;.;*: 3ot Tap Connections

SA%S;.;'** Applicable Codes and Standards for $ressure $iping Systems

SA%S;.;'*' /egulated 0endors .ist for $ipes and


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ADDEND$# C1 INS$%ATION INSPECTION C8ECB%IST

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Documents

PEW-405.01 Inspect New Piping