STUDY & TEST GUIDE FOR NEW MECHANICAL QC

(PIPING/HYDRO/WELDING)
1. The following Mechanical SATIP Folders (for your Focused Assessments) are used.
 SATIP-A-004 (Contains SAES-A-004, SAES-L-150, GI-2.102 & applicable SAICs).
 SATIP-L-108 (Contains SAES-L-108 & Checklists) for Valves
 SATIP-L-052 (Contains SAEP-351 & Checklists) for Hot Taps
 SATIP-L-350 Series - Plants or 450 - Pipelines (SAES-L-350/450) as applicable
 SATIP-L-410 & 420 for Pipelines (Well Head Piping & Scraper Trap Stations)
 SATIP-W-011 & 012 (SAES-W-011 or SAES-W-012 as applicable)
 SATIP-J-600 (Relief Valves) & SAES-J-600, SAEP-318/319 covering Pop Testing
 SATIP-J-900 (Instrument Air Piping) covering SAES-L-110 & SAES-J-900
2. Open the Spec Awareness Folder (SAES-L-105, Spec Awareness & Spec-Check)

Meet your candidate and make him comfortable on his interview. Ask him what
reading he has accomplished so far regarding the Saudi Aramco Standards & SATIPs.
Depending on his answer, you have several options as follows:
Candidate Knowledge of SA STDs & SATIPs
1. He has read nothing and understands little of his new responsibilities.
2. He has read little but seems to understand the basics of his responsibilities.
3. He has read the Standards & has not covered the SATIPs he is responsible for.
4. He has read both Standards & SATIPs and is ready to discuss them with you.

Note: Schedule Q allows time for new Inspectors to perform required reading and adapt
to their new responsibilities (SATIPs) on their arrival. Those Inspectors that show ability
to handle new responsibilities (on initial questioning in interview) & have performed the
required reading and can intelligently discuss points of Inspection interest can be fully
interviewed and accepted if they demonstrate the basic skills needed for the work. All
accepted candidates are subject to satisfactory field performance. It is poor practice to
conditionally accept new candidates (even on trial basis) without any required reading.
For those who rate # 1 & 2 give them a task for required reading (STDs &/or SATIPs),
thank them for coming for interview and send them back to their QC Manager with the
notice that they are not ready for interview/testing. Inform SAPMT that they are not
ready for interview/test & were tasked for required reading. Entry into E-Logbook!!!
For those who rate # 3 or 4, you can proceed with interview and questions related to the
work. Develop your own style of interviewing using checklists and your own experience
including any Lessons Learned.

REMEMBER, THOSE NEW TO SA HAVE NEVER WORKED WITH SA STDS!

Be willing to pass along your experiences with the SA STDs & Checklists, and stress the
importance of using Scope, Index & References when reading SA Standards.
1. USE CONTRACTOR’S PIPING SPECS (LINE CLASS SUMMARY & SPECS) 2. USE
A SAMPLE ISOMETRIC DRAWING & P&ID DRAWING
NOTE: THEY ARE ABLE TO READ THEIR OWN COMPANY ISOs!!!
 Can Identify the lowest point elevation on all drawings
 Can Identify any Mark Numbers on drawings (samples given)
 Can Identify any unusual features or items to be removed for hydrotest (orifice flanges,
equipment, filters, traps, check valve internals, etc)
 Can Identify any valves requiring field hydrotesting
On each Drawing, the candidate can identify the following when you ask him:
 Line number
 Piping Class
 System & Flange ratings (Limiting factors for hydrotest)
 Gasket types
 Special Notes (P&IDs)
 ISO & P&ID Symbols (blinds, valves, etc)
For Special Processes (Welding, NDE, Positive Material ID, PWHT/BHT, Pressure Testing,
Gasket Installation, Gap Control of Socket Welds & Threaded Joints) that are related to
Piping Installations, Candidate has a basic understanding of all requirements and knows
which SATIPs & checklists he must reference:
1. SAES-W-011 & SAES-W-012, applicable SATIPs & SAICs & SATRs
 Heat Treatment & Associated Hardness Testing (NACE RP0472)
 Weld/NDT Tracking, Welder Performance, Consumable Control
 NDT SATIPs & Controls over Subcontractors (RTFI Attachment)
 Gap Control for Socket Welds & Threaded piping (seal welding)
2. SAES-A-106 (PMI) & Color Coding (Pipe, Fittings, Gaskets, Special materials)
3. SAES-A-004 (Pressure Testing) & applicable SATIPs & SAICs & SATRs
 SAES-A-007 (Test Fluids/Lay up)
 SAES-L-108 (Valve Testing) & SATIPs (SAICs & SATRs)
 SAES-L-150 (Pressure Testing)
4. SAEP-351 (Mandatory new requirements for Gasket Installation)
 Friction Factors
 Torque value tables
o Stud Tightening Sequence
o Be able to identify different type of gaskets/color coding per procedures
o Specs & color code table for differing gaskets
5. SPECIFICATION AWARENESS (SAES-L-105, Spec Awareness & Spec-Check)
 SAES-L-105 (Piping Material Specifications)
o Line Class Designations
He must know SA Line Class Designation & Service Codes.
See Sect. 7, have candidate break down the following (example)
6”-CA-127-1CS3C is listed on the Isometric Drawing
Answer: 6” = Line Size, CA = Caustic Service, 127 = Line Id number.
1CS3C = 1 = Press Rating @ 150 #, CS = Matl, 3 = Corr Allow 4.8mm, C =
Service (Caustic)
o Branch Connection Tables (candidate can use table)
What type of connection is acceptable for a 24” header, 12” branch?
Answer: Weldolet or branch welds with reinforcing pad.
o Valve Trim Table
25-STEP BASIC PRE-HYDROTEST CHECKLIST (Interview Discussion Material)
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). PMI reports reviewed/OK.
HIC Testing Certs available.
5. Correct rating of materials (flanges, forged fittings). Determine test limitations (psi).
6. Branch reinforcement meets SA standards and piping specifications.
7. Orifice flanges flush, seal welded internally and in correct orientation. NDT (PT) &
visual inspection of internals documented and accepted prior to flange tensioning.
8. Piping installed plumb and level, slope angle correct where required. 50MM minimum
clearance can be obtained, especially after insulation. Dead legs are not within 625mm of
structural supports.
9. Weep holes and vent holes in reinforcement and wear pads. Air testing completed, OK.
10. Seal welding of threaded connections completed to the first block valve.
11. Valve types, location and orientation correct. Field hydrotesting report acceptable.
12. Correct bolts installed and identified. Stamping of hardware meets specifications.
13. Temporary gasket locations have been identified for gasket reinstatement on dwgs.
14. Correct gasket type, size and rating. Reports/dwgs for Gasket installation accepted.
Color-coded marking on hardware by QC has identified final torque acceptable.
15. Permanent supports and guides are installed. Temp. supports (if needed) installed.
16. All welding completed and documented, QC reports available.
17. NDT completed and all outstanding repairs completed, accepted and documented.
18. PWHT and hardness testing completed accepted and documented.
19. Water quality analysis requirements for flushing (12 inch and below) and filling are
determined and Reports/certs are available. Chemical additives to flushing and test water
for heater coils and headers and other specialty items have been determined.
20. Flushing of lines to 12” diameter with appropriate quality water/chemicals has been
performed. Cleaning with air and rags on lines 14” and above has been completed.
Flushing Certificate accepted.
Procedure requirements for keeping covered/cleaning piping under construction
21. Check valves and/or flappers removed.
22. Instruments (level gauges, relief valves, control valves, orifices, etc) isolated, gagged
and removed as required by SA standards.
23. Strainers, filters and in-line components removed as required by SA standards.
24. High point vents fully opened prior to and during filling to remove air from the
system. Low point drain available and identified as required.
25. 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 piping? 1%.
Example: 24” piping is 610mm. One joint can be 610 x 610 (oval), another can be 604 x
616 (1% out & within tolerance). When matched for fitting, how will internal alignment
of piping meet 1.5mm tolerance in SAES-W-011.
Crescent technique for repairing ovality is required (method statement). Crescent is (2)
12mm crescent shaped plates separated by steel bar center that distributes load and
bearing force and increases efficiency, doubles production by and reduces potential
damage to piping. Jacking limits (30 ton maximum for CS, much less for SS) to 25mm
max. Cold bending and forming repairs including rolling thick repads require a method
statement and must conform to ASME B31.3. Hammering on steel is not allowed and
evidence of hammer marks is cause for rejection and removal of affected item.

Preheat
Determine Process
1. SMAW ONLYFollow CE determination values in Drawings and Tables 3, 3A
notes of SAES-W-011 for pipe, fitting, and flg.
2. GTAW or GTAW/SMAWFor field fabrication or repair of carbon steel materials (all ASME P-No. 1 materials,
including API grades up to and including X60), use preheats listed in Standard Drawing W-AE-036451, sheet 1-8
Mill CE Values GTAW Heat Input Combined Determine Preheat
Certs Process Thickness Requirements from
Table for GTAW

Flanged Joints (PIPs, PNSC series, Checklists, PFI-ES-3)

What are the different types of mating flanges? Name the 4 most common RFWNF,
RFSO, RTJ, and FF
Describe good inspection practice during gasket installation? List common problems
associated with poor practice.
TPSA 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
What is often overlooked during orifice flange fabrication? Grinding butt welds flush and
seal welding orifice.
What NDT methods are required during orifice flange installations? Visual and PT/MT
Flange tolerances during construction are found where? SAES-L-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.
When a flange connects to a pump or other equipment, is there any special tolerance
involved? Yes, Mfg tolerance.
Threaded Joints (SAES-L-010, PIPs, Checklists)
What is the maximum diameter piping allowed in hazardous service? 1-1/2”
What is the minimum sized piping that can be installed on pipe racks? 1” (AB-036207-
Pipe spacing)
What is the required thread engagement for piping at SA and where can it be found?
What is the requirement for seal welding at SA? SAES-L-010 and specifications.
Can Teflon tape be used prior to seal welding?
How many threads can be visible after seal welding threaded joints? Zero, seal welding
must cover all threads.

Socket Joints (SAES-L-010, PIPs, Checklists)

What is the gap requirement for socket welds for new construction? 1.5mm to 3mm gap
prior to welding.
What is the best way to assure consistent gap is maintained? Use of gap-o-let rings
What is the minimum fillet weld size for a socket welded connection? 1-1/4t but not less
than 3.2mm.
What are common failures in the quality system during fit up that leads to hydrotest
failures? Failure to properly clean, deburr and degrease fittings and piping prior to
welding. Oil residue from cutting causes thru weld porosity and leakage during hydro
tests.
Welded Branch Connections (SAES-L-105, PIPs, TPSA Piping Specs, Checklists)
Ensure SA STD dwg AE-036175 is used and followed extensively related to welding
bosses.
Before fitting repad over branch, what requirements for SA work applies?
1. Follow Spec Branch Connection Tables and Std drawings to determine required
construction.
2. Have the tell-tale holes for air testing been drilled, tapped, deburred and oil
removed by cleaning (sandblasting)
3. Has the branch to header weld been welded flush, NDT performed, accepted prior
to fit up of repad.
4. Has the repad been properly cold worked and radiused to meet the piping OD and
assure good fit up. No hammer marks.
5. Do not allow flange tack welding above the branch connection until the repad fit
is acceptable. Maximum gap is 1.6 mm.
6. A 6 mm gap maximum is allowed between repad and branch for root opening.
7. Follow preheat tables and W-011 requirements for GTAW & SMAW process on
welding
Supports (ISOs, Piping Specs, Checklists)
What critical overlooked requirement on support installation causes the most rework?
Fit-up, elevation and slope per AFC drawings, this checked by survey or level (string
line) in accordance with PIPS and procedures.
What is an expansion loop? Draw a picture
What is an anchor? Draw a picture
Where is an anchor required? Draw a picture
What is the required freedom of movement for anchors? As shown on drawing,
clearances are critical
What are these tolerances for anchor locations? As shown on drawing, none if no
tolerance is shown.
What is a guide? Restrains piping movement, as shown on drawing
What is a stop? Restrains piping movement, as shown on drawing
Where are they required? On and adjacent to structural supports
When should anchors, guides, etc, be welded in place during construction to prevent
rework from movement?
After the line has been checked, the last thing before hydrotest & punching is to weld
restraints (anchors, guides, stops, etc).
What is a saddle support and what minimum spacing from structure to pipe must be
maintained? 100mm or as shown on dwg.
When should shims be installed? To correct movement and correct misalignment and
provide full bearing of support as needed.
Give examples of unique support details that allow piping freedom of movement for
thermal expansion? Teflon slides/wear pads, Spring hangers, hydraulic snubbers,
expansion joints. Closely follow drawing details and notes related to installation
Clearances (SAES-L-011, 12)
 REVIEW ISOs closely for obvious violations before piping construction
Piping spacing per AC 036207 and 50 mm rule between all piping and supports (Lessons
Learned)
24” clearance from supports dead legs and drains, vents------------ Small diameter ,
300MM from grade @ all piping.
Fittings, butt welds, etc, adjacent to hangers, clamps, supports, etc must be spaced to
allow freedom of piping movement. Alternatively, flush gind and NDT can be allowed as
long as weld location will not restrict piping movement.
Know clearances listed in Section 5 & AC drawing 036207.
Valves (SAES-L-108)