Saudi Aramco Inspection Checklist

SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.
00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Hot Tap & Stopple Connection Installation
SAIC-L-2090 30-Apr-17 MECH-
(Per SAEP-311, 13 September 2009)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIM
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIR
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DA
No.
A General Requirements (See Notes 1, 2, 3)
Each Hot Tap & Stopple Connection Installation is Controlled from the design
phase through Completion utilizing the following requirements:
A) Latest Edition of SAEP-311 (Install. of Hot Tapped & Stopple Conns)
SAEP-311
A1 B) Materials are per latest approved edition of 02-SAMSS-006.
(Procedure)
Procedure details design package content
per SAEP-311. Procedure shall be approved prior to the
start of work by SA.
Procedure follows the sequence of operations outlined in SAEP-311 for HOT TAP
SAEP-311
A2 INSTALLATION for welded connections to pipe, pressure vessels and tanks while
(Procedure)
in service. See Attachment 1.
Procedure follows sequence of operations outlined in SAEP-311 for PLUGGING

SAEP-311
A3 PIPELINES THROUGH HOT TAPPED CONNECTIONS (ALSO KNOWN AS
(Procedure)
STOPPLING). See Attachment 1.
Procedure States*: Hot tapping & stoppling are complex operations to be

performed by trained techs with support of experienced engineers. SAEP-311,
A4
Only skilled welders and fitters Section 1
with experience in Hot Tap Activities shall be utilized for Hot Tap work.
Procedure States: Personnel responsible for work are fully trained in use of
SAEP-311,
A5 procedure & shall be carefully supervised by experienced Engineers &
Section 1
Construction Supervisors during execution of HOT Work
Procedure references & has Attached the following Forms:
SAEP-311,
A6 See Attachment 1 for a complete list of Latest
Appendix A
Forms Req'd
Procedure Definitions Include the following per SAEP-311:

Stopple: A stopple is an articulated pipe
plugging device, normally inserted through a stopple split tee with a full line size
hot tapped opening, while the line is pressurized. Saudi Aramco has stoppling
equipment for pipe sizes from 1" to 60". Stopple Split Tee:
A stopple split tee is a fitting designed with dimensional requirements to suit the SAEP-311,
A7 stopple plugging head. These fittings shall be purchased in accordance with 02- Section 4
SAMSS-006. Sandwich Valve: This is a gate valve (Definitions)
designed to have a short face to face dimension used as a temporary valve for
stoppling. They are also used for hot tapping when the connection will only be used
temporarily or when the reach of the hot tap machine is insufficient to complete a
hot tap through a conventional valve. These valves cannot be operated unless the
pressure is equalized across the gate..
Saudi Aramco: Company General Use

Hot Tap: Hot tapping is technique, performed using specialized equipment for
cutting a hole in a pipe or tank through a welded or bolted branch connection while
they are under pressure.. Lock-o-Ring Flange and Plug:
This is a special flange and plug assembly designed to allow the recovery of the
SAEP-311,
hot tap valve while the pipeline is under pressure. The L-o-R plug has an o-ring
A8 Section 4
seal on its circumference and can be lowered into the bore of the L-o-R flange,
(Definitions)
using a hot tap machine. The L-o-R flange has retractable segments that can be
advanced into a groove in the circumference of the plug above the o-ring. These
segments retain the plug in position so that the valve can be depressurized and
removed and replaced with a blind flange or permanent valve.

R NUMBER
NTRACTOR
PLANT NO.
MCC / MCC NO.
TRAVEL TIME
MCO USE ONLY
WORK PERMIT REQUIRED?
RE-INSP DATE

SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.00 31-Mar-15
ITEM
No.
B FIELD ENGINEERING & INSPECTION RESPONSIBILITIES (DESIGN, DOCUMENTATION & DRAWINGS)
Procedure details FIELD ENGINEER & INSPECTION RESPONSIBILITIES:

SAEP-311,
B1 A) Field Verification of Data for Calcs
Section 5
B) Inspection & Evaluation of Results
Procedure ensures Documentation of Design Pkgs & Work Activities includes docs SAEP-311,
B2
& drawings listed in Section 12. Section 12
Procedure ensures Pressure Testing & Inspection Section includes all the checks SAEP-311,
B3
and requirements listed in Section 14. Section 14
C STOPPLE SPECIFIC SAFETY MEASURES (SECTION 15)
SAEP-311,
C1
Para. 15.1.1

ITEM
No.
SAEP-311,
C2
Para. 15.1.2
SAEP-311,
C3
Para. 15.1.3

ITEM
No.
SAEP-311,
C4
Para. 15.1.4
SAEP-311,
C5
Para. 15.1.5
Stopples cannot be guaranteed to seal 100%. A small amount of

leakage should be expected and a secondary barrier with a bleed
SAEP-311,
C6 connection between the stopple and the secondary barrier should be
Para. 15.1.6
planned for. The secondary barrier could be a balloon and mud pack,
sealing scraper, mechanical plug or similar device.
D MATERIAL RECEIVING & MATERIAL REQMTS (PROCEDURE SPECIFIC) ... Utilize Checklist SAIC-L-2092 with this Section
Procedure ensures Materials Received meet 02-SAMSS-006 Requirements as SAEP-311,

D1
detailed in Attachment 4. See Also SAIC-L-2092. Section 13
Procedure has these elements & they are strictly followed.

1) Mat'ls are uniquely identified by Hot Tap/Tie-In number
2) Matl's are segregated after such ID (mark & organize)
3) Markings are low stress stamp (coating applications) 4) Sch. Q, Att
Matl's are stored & preserved after receipt. Valves that require Field Testing VI,Para-3-5
D2
are so tested and properly preserved. Coating of materials shall ensure no Tables & SAEP-
loss of traceability. 5) Matl's that 311 (Procedure)
require cutting & distribution into segments have id (by low stress stamp)
transferred before cutting. 6) Mixing of any
mat'ls is prevented by Quality Controls.
E DESIGN PACKAGE & DESIGN SPECIFICS (From Item A1) ... Note: Design Package "Content" is listed in Procedure.

ITEM
No.
Design Package: The initiating organization* shall prepare a design package for
each hot tap that will include fully dimensioned drawings, a materials list, Direct
SAEP-311,
E1 Charge Requisitions and welding procedures.
Para. 5.1
The design package shall be approved by Hot Tap Group.
SAPMT is the initiating Organization
Hot tap connections shall be designed for the Maximum Allowable Operating SAEP-311,
E2
Pressure for tapped equipment per applicable ASME code. Para. 9.1
The dimensions of the connection, the hot tap valve, and clearances shall be within
the limits specified for the hot tapping equipment to be used. Hot-Tap and Stopple SAEP-311,
E3
Unit should be contacted to provide this data prior to purchase of any fitting with an Para. 9.2
extended branch nipple.
The minimum valve bore shall be large enough to pass the cutter. The valve seat SAEP-311,
E4
lugs shall not restrict the opening. Para. 9.3
A tap equal to the nominal size of the header (such as required for stoppling of a
SAEP-311,
E5 pipeline) shall be made only when accurate positioning of the cutter can be
Para. 9.4
guaranteed.
In hot tap cases other than those for stoppling purposes, the cutter should be at SAEP-311,
E6
least one pipe size smaller than the pipe to be tapped. Para. 9.5
If the hot tap is to be used for stoppling the pipe, the hot tap crew shall take
measurements and mark the tapping location prior to welding of split tee to ensure
that the pipe out of roundness meets the tolerances in the following table:
SAEP-311,
E7
Para. 9.6
Adequate support of the hot tap machine shall be provided to prevent

SAEP-311,
E8 overstressing of the pipe and/or fitting, particularly in cases where the hot tap
Para. 9.7
sticker is not installed in a vertical position. Staging often req'd.
Storage Tanks: For atmospheric or low pressure hydrocarbon storage tanks, hot
tap connections shall be located at least 1 m (39 inches) below the liquid level
while welding or hot tapping is in progress.
SAEP-311,
E9 A) If the tank or vessel is in service during the welding or hot tapping
Para. 9.8
process, the operating organization must ensure that the liquid level
above the level of the weld or cut shall not be less than 1 meter.
B) Connections on tanks shall meet the requirements SAES-D-108.
F INSTALLATION & WELDING (HOT TAP & STOPPLE SAFEGUARDS & LIMITATIONS, ADDITIONAL DESIGN CHECKS)
Procedure ensures Restrictions are listed & steps are taken to assure that Work is SAEP-311,
F1
strictly controlled. Section 6
Procedure ensures Installation & Welding Section includes all the checks and SAEP-311,
F2
requirements per Section 13. Section 13
G Safety Requirements
SAEP-311,
G1 Procedure ensures Safety Requirements are identified and met.
Section 7
REMARKS: UPON AGREEMENT, THIS CHECKLIST & SAEP-311 in entirety may be used in lieu of a Procedure.

ITEM
No.
NOTES: 1. Copy and paste as much of checklist into finished procedure as possible. SAEP-311 = Procedure = This Checklist
2. June 3 2008 Version of SAEP-311 has been utilized & referenced here (Pipeline Safety). Utilize latest edition regardless of date (Safety).
3. Quality Managers shall ensure the correct and thorough development of procedures & Design Packages using this checklist.
4. SAES-L-052 is no longer utilized for Hot Taps. SAEP-311 is MANDATORY. SAEP-310 requirements may also be mandatory in the event
that damage assessment & Pressure Piping Considerations come into the picture due to Inspection Findings (HIC Damage, etc).
5. Utilize SATR-NDE-2007 for HOT TAP UT REPORT (Appendix A4). UT Results shall be *current. *Utilize 30-day rule in Procedure.
ATTACHMENT 1: SAEP-311, Appendix A (Applicable Forms)

Appendix A1 - UT Thickness Measurements
Appendix A2 - Hot Tap Reinforcement Data & Calculation Sheet (Form 7827-ENG) PG 1, 2 & 3
Appendix A3 - Hot Tap Data & Checklist (Form 7235)
Appendix A4 - Hot Tap & Stopple Measurements Form PG 1 & 2
REFERENCE DOCUMENTS:
1- SAEP-311 -- Installation of Hot Tapped & Stopple Connections, (01March 2013)
2- SAEP-310 -- Pipeline Repair and Maintenance (10 March 2012)
3- SAES-A-004 -- General requirements for Pressure Testing (30 Jan 2011)
4- SAES-D-008 -- Repairs, Alterations, and Re-rating of Pressured Equipment 30 June 2014.
5-SAES-W-010 -- Welding Requirements for Pressure Vessels 08 September 2012.
6-SAES-W-011 -- Welding Requirements for On-Plot Piping (16 December 2013)
7-SAES-W-012 -- Welding Requirements for Pipelines 08 September 2012.
8. SASD AB-036719- Sht-001-Rev-11--Reinforcement of Welded Branch Connections
9- 02-SAMSS-006 -- Hot Tap and Stopple Fittings, (6 September 2011)
Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FA

R NUMBER
NTRACTOR
RE-INSP DATE

R NUMBER
NTRACTOR
RE-INSP DATE

R NUMBER
NTRACTOR
RE-INSP DATE
tion

R NUMBER
NTRACTOR
RE-INSP DATE

R NUMBER
NTRACTOR
RE-INSP DATE
ty).
vent
Work Verified
Work Verified
Work Verified
Y = YES N = NO F = FAILED

SAEP-311 Appendix A - APPLICABLE FORMS for HOT TAP & STOPPLE INSTALLATION

QR NUMBER
BLE FORMS for HOT TAP & STOPPLE INSTALLATION


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SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Procedure follows sequence of operations outlined in SAEP-311 for PLUGGING

Procedure States*: Hot tapping & stoppling are complex operations to be

Procedure Definitions Include the following per SAEP-311:

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

MCC / MCC NO.

Saudi Aramco: Company General Use

B FIELD ENGINEERING & INSPECTION RESPONSIBILITIES (DESIGN, DOCUMENTATION & DRAWINGS)

Procedure details FIELD ENGINEER & INSPECTION RESPONSIBILITIES:

C STOPPLE SPECIFIC SAFETY MEASURES (SECTION 15)

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Stopples cannot be guaranteed to seal 100%. A small amount of

Procedure ensures Materials Received meet 02-SAMSS-006 Requirements as SAEP-311,

Procedure has these elements & they are strictly followed.

Saudi Aramco: Company General Use

Adequate support of the hot tap machine shall be provided to prevent

Saudi Aramco: Company General Use

ATTACHMENT 1: SAEP-311, Appendix A (Applicable Forms)

Contractor / Third-Party Saudi Aramco

QC Inspector PID Representative

QC Supervisor Proponent and Others

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FA

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

BLE FORMS for HOT TAP & STOPPLE INSTALLATION

Saudi Aramco: Company General Use

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