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GUIDE FOR TESTING QC CANDIDATES (UG

PIPING/HYDRO/WELDING)
ADD SATIPS FOR UG PIPING TO THIS LIST & SAICs FOR
PUNCHLISTING
ADD PLANT FIREWATER SAES-B-017/019 & SATIPs ...
Section 12.6
ADD SATIPs SAES-S Series (S-010, 30, 40, 50, 60, 70 all)
SATIP-L-350 related to UG Piping (Understands connection)
Have copies of other applicable piping/hydro standards at Test
site, have open book discussion forum with candidate.
Allow candidate time and stress the importance of using
Scope & Index when referring to Standards or searching
for references. USE PLANT PIPING CHECKLIST AS
REFERENCE FOR TEST & ISO drawing Test
Identify the lowest point elevation on all drawings
Identify any Mark Numbers on drawings (samples given)
Identify any unusual features or items to be removed for
hydrotest
On each Drawing, list the following at the bottom of the
drawing:
Line number
Piping Class
Flange ratings
Gasket types
Limiting Factor for Hydrotest
Medium for testing
SAES-A-004 (Pressure Testing)
SAES-L-105 (Piping Material Specifications)
o Line Class Designators
Where are the Saudi Aramco Line Class Designators
and Service Codes. See Sect. 7, have candidate
break down example of 6-CA-127-1CS3C.

6 = Line Size, CA = Caustic Service, 127 = Line


Identification #, 1 = Pressure Rating @ 150#, CS =
Matl, 3 = Corr. Allow 4.8mm, C = Service (Caustic)
SAES-S-020, 030, 040, 050, 060, 070
SAES-L-150 (Testing of Plant Piping)
GI 2.102 Pressure Testing Safely
Pre-Punch Checklist
1. Lay-up procedure and estimated service date has been
determined (60-day rule).
2. Line completed and in compliance with SA standards &
Isometrics (as built or redlined dwgs available during
punching).
3. System boundaries have been clearly identified and
temporary blinds have been installed per hydro test diagram.
4. Correct Construction Materials utilized (grade/schedule).
Color-coding (green).
5. Correct rating of materials (flanges, forged fittings).
Determine test limitations (psi).
6. Branch reinforcement meets SA standards and TPSA piping
specifications.
7. Piping installed plumb and level, slope angle correct where
required.
8. Weep holes and vent holes in reinforcement and wear pads.
Air testing completed, OK.
9. Valve types, location and orientation correct.
10. Correct bolts installed and identified. Stamping of
hardware meets specifications.
11. Temporary gasket locations have been identified for gasket
reinstatement on dwgs.
12. Correct gasket type, size and rating. Reports/dwgs for
Gasket installation accepted.
13. Color-coded marking on hardware by QC has identified
final torque acceptable.

14. Permanent supports and guides are installed. Temp.


Supports (if needed) installed.
15. Water quality analysis requirements for flushing/testing
16. High point vents fully opened prior to and during filling to
remove air from the system. Low point drain available and
identified.
17. Pressure gauges installed (2 minimum), with relief valve
calibrated as required for 5% over pressurization.
General Information
What is an Inspection & Test Plan? A mandatory item in the
Quality Plan that guides and assures quality in a specific type
of work in a specific sequence of QC activity steps.
What is a Quality Control procedure? A document that details
the specific steps needed to fulfill the QC activity in the ITP
What is a Quality Control Form? A written documentation
detailing a specific activity in the ITP & QC Procedure
What references will be found in ITPs? SA STDs, Procedures
and code references, specifications
What is a specification? A specification is a guideline to assure
that minimum quality standards are met
What 4 types of Inspection Action points are found in the ITP?
Hold, Witness, Surveillance, Review
Explain the differences between the 4 types of Inspection
points? Detail answer and ensure a clear understanding by
candidate
What is a P&ID? Piping and instrument Diagram will show the
piping layout and detailed notes relating to piping and
instrumtation.
What is an SIS? Safety Instruction Sheet that gives full design
details related to a piping system or line.
What is a piping system? Describes the specific service or
fluid.

What is the piping line class designation? A specific name in


alphanumeric designation describes features of a piping
system.
Give an example of a line designation from Isometric Drawing?
1CS1P3 = 150# class, Carbon Steel, 1/16 CA, General
Hydrocarbon
What is an isometric drawing? A detailed piping system/line
drawing with reference to construction and material
requirements
What things are found in a Piping Isometric drawing? Line
conditions, references to drawings, materials of construction,
continuations, orientation, piping and drawing details and
notes, revision control and approval status.
What is a Material List or Material Take-Off Sheet (MTO)?
Details of materials used in construction of Isometric.
What is a PIP? Process Industry Practice details requirements
for fabrication as Industry Practice. These are often the basis
for SA stds
Give an example of a PIP? PNSC 0001, PNSC 0011, PNSC 0021
What kinds of information and requirements are found in
PIPs? Common industry practices for manufacture &
construction
Name the different types of Service Conditions? Temperature,
pressure and fluid type
Material Inspection
Match physical condition in field to service condition shown on
ISO/P&ID/SIS
How do you verify (name several items to check) that the
correct piping material is used? Mill Cert, heat number,
color-coding & PMI, schedule, rating, Carbon Equivalent
value for PREHEAT, diameter, class, grade.
How do you identify fittings and flanges? Correct ratings,
sizes, class, schedules as marked on fittings & mill certs

How do you check piping for the correct schedule? Use a


Vernier Caliper and ensure piping is within tolerances.
What are the tolerances for physical piping straightness
and defects? Check the ASTM or API piping specification.
What is the standard mill tolerance for piping? 87-1/2%
(all) to 115% (greater than 2), 120% (2 & less) of
nominal
Valves of the correct rating and material. Check
materials, CMTRs & trim during Valve Testing (Visual
inspection)
Ovality
What is the tolerance for ovality of RTR piping?
How can piping stacked too high be damaged?
Flanged Joints (SAES-L-050, PIPs PNSC series, Checklists,
PFI-ES-3)
Describe good inspection practice during gasket installation?
List common problems associated with poor practice.
Gasket installation checklist approved is the correct answer.
Detailed discussion to follow.
What is the requirement for bolting and torqueing flanges at
SA? SAES-L-050, Tables and applicable procedure
What is a friction factor?
What is the difference between torqueing CS and SS bolting?
Yield strength is greater in Carbon and torque values are
greater
Does the use of galvanized bolts require any special torqueing
consideration, or can the CS bolt torqueing values be used?
What is a spectacle plate? Mandatory SA Std dwg with plate
used for service and shutdown (isolation) for maintenance
purposes
What are jackscrews and when are they required? They are
located at flanged connections to facilitate maintenance and
removal of spectacle and orifice plates to facilitate
maintenance

Flange tolerances during construction are found where? SAESL-050 & PFI-ES-3.
Describe how flanges can be misaligned in different
directions? Rotational offset & hole misalignment, misaligned
vertically & horiz
What is cold spring? Application of mechanical stress (bending
twisting pulling) upon a piping segment to achieve bolting and
connection to another segment. Is cold spring acceptable? No
How can an inspector determine if cold spring exists visually
on a flanged section of piping? Visual determination is easy.
Close inspection of flanged connection and any visible
deformation, especially in small diameter sections.
Clearances (SAES-S-070)
REVIEW closely for obvious violations before piping
construction
Candidate must be able to discuss easily clearances required
in SAES-S-070