UPGRADE GAS FLOW CAPACITY

BIN QURAYA EST.

(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

DOCUMENT TITLE

QUALITY CONTROL PROCEDURE

For
Flange Tie-In Procedure of 24” Gate Valve and 24” Flow
Meter
Inlet of Crude Line, Tie-In No.: Q86-004 & Q86-005
& Q87-007, 24”-P-0008- 3CS1P1

CLIENT: SAUDI ARAMCO

CONTRACTOR: BIN QURAYA EST

01 01 MAR 2015 Issued for Review/Approval

Prepared by: Reviewed By: Approved BY: Approved by: Approved BY:
Rev. Date Description
(QAM) (PM) SAPMT Proponent SAPID
RESPONSIBILITIES
This document is the responsibility of the Quality Assurance and Quality Control Department.
The Project Quality Assurance Manager is responsible for the maintenance of this document and for arranging controlled distribution through
Project Document Controller.

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 UPGRADE GAS FLOW CAPACITY
BIN QURAYA EST.
(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

Table of Contents
SL NO DESCRIPTION PAGE

1.0. SCOPE 3 of 7

2.0. PURPOSE 3 of 7

3.0. REFERENCES 3 of 7

4.0. RESPONSIBILITY 3 of 7

5.0. PROCEDURE 4 of 7

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 UPGRADE GAS FLOW CAPACITY
BIN QURAYA EST.
(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

1.0. SCOPE:
- This procedure covers the requirements for all Flange tie-in and other applicable
standards, but not limited to references listed below. Scope of work covers the line
identification, Tie-In marking, Isolation, with attachment of specific method of
statement applicable to this Flange Tie-In procedure. This procedure shall be
performed with system shutdown & any safety precautions shall be as per approved
JSA.
2.0. PURPOSE
- This Procedure is to establish an identification system that shall uniquely identify each
said activities, So that any data related to that particular job can be traced out at any
stage of the project.

3.0. REFERENCES
SAES-L-100 : Applicable Codes & Standards for Pressure Piping Systems
SAES-L-105 : Material Specification for Piping Systems
SAES-L-109 : Selection of Flanges, Bolts and Gaskets
SAES-L-125 : Safety Instruction Sheet for Piping & Pipeline
SAES-L-350 : Construction of Plant Piping
SAEP 351 : Assembly of Bolted Flanged Joints
SAIC-L-2025 : Review of Tie-In Package and Tie-In Procedure
SAIC-L-2029 : Inspection of Tie-In Materials
SAIC-L-2014 : Inspection of Bolted Flanged Joint Assembly
SATR-L-2001 : Flanged Joint Tightening Inspection Report
SATR-A-2011 : Final Inspection / Re-Instatement Punch list
SAUDI ARAMCO Typical Inspection Plans (SATIPs)
SAUDI ARAMCO Inspection Checklists (SAICs)
SAUDI ARAMCO Test Report (SATR)

4.0. RESPONSIBILITY: (Responsibilities shall be as defined below for every activity to be performed)
- Bin Quraya EST: BQE is Responsible for control and issue of relevant construction
drawings/piping isometric drawings to those sections requiring them to perform their
tasks. Ensure that where required all Identification and Spool Marks are identified on
the drawings prior to issue to the field Construction and QC department.
- Site Superintendent / Engineering department: Site Superintendent is Responsible
for collecting IFC drawings from BQE Document Controller and also responsible for
updating if any revisions or changes to the drawing.
- BQE Field Engineering department: Shall provide the QC with controlled copies of all
IFC drawings and any revisions of these drawings. Field Engineering dept. assigns and
indicates such information as Spool Number, Weld Number and Shop Weld/Field Weld
designation to the IFC drawings, prior to issuance to the QC department.
- QA Manager: QAM is Responsible for reviewing the technical content of projects and
providing as early as possible a sequence of operations suitable for inclusion in the

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 UPGRADE GAS FLOW CAPACITY
BIN QURAYA EST.
(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

Inspection & Test Plans. QC dept. receives weld maps and controls them in accordance
with Approved procedures.
- Quality Manager/ QC Supervisor: Should be responsible for compliance of this
procedure and shall guide the respective teams to fulfill the requirements of this
procedure.
- Quality Control Welding Inspector: QCI Welding Ensures compliance to this
procedure for the unique identification of welds (completed or otherwise) on
fabricated items relative to shop and field fabrication.
- Welding QC Inspector shall accompany the CLIENT representative to carry our all
routine Welding & NDT Inspection and release hold points by signing and obtaining the
CLIENT representative approval signature on various approved quality records as
proof of Inspection confirming to the Specifications as per approved SATIP.
- The Mechanical Quality Control Inspector shall accompany the CLIENT
representative to carry out routine Inspection and release hold points by signing and
obtaining the CLIENT representative approval signature on the various Quality Record
as proof of Inspection conforming to Specifications. The Mechanical Quality Control
Inspector shall co-ordinate with other discipline Quality Control Inspector for ensuring
that all other discipline activities that require inspection within the above activities
have been inspected and approved.
- The Construction Supervisor shall be responsible for the observance of all safety
precaution required by the BQ Safety Plan and where applicable the CLIENT safety
indication (JSA).
- Welding Foreman: Foreman ensures that all welders in his crew were marked their
unique Welder Symbol and indicate Date Welded prior to leaving the work location.
- Welders: Each weld must be marked with the welder’s unique identity symbol and the
date of welding.

5.0. PROCEDURE:
5.1. Tie-In by Flanged Connection.
5.1.1. A tie-in package for Flanged connections shall be prepared according to
SAIC-L-2025 and submitted for review and approval prior to the tie-in
activity.
5.1.2. The QC Mechanical Inspector shall be responsible for the inspection of all
tie-in Materials.
5.1.3. The acceptance criteria for the inspection of tie-in materials shall be those
SAIC-L-2029.
5.1.4. The tie-in package shall have the following Information:
5.1.4.1. Tie-In Information:
a. Tie – In Number: Q86-004, Q86-005 and Q87-007
b. Line Class Header: 24”-P-0008-3CS1P1
c. Line Class of Branch: 24”-P-0008-3CS1P1
d. Fluid Service: Crude Oil

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 UPGRADE GAS FLOW CAPACITY
BIN QURAYA EST.
(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

5.1.4.2. Tie – In Materials Descriptions:

a. 24”XCL300# Gate Valve A216 WCB (2 Nos)
b. 24” X CL 300# Ultrasonic Flow Meter (1 Nos)
c. 24” X CL 300# Spiral Wound Gasket (6 Nos)
5.1.5. The Mechanical Engineer shall ensure the tie-in materials are physically
present and properly identified in their respective locations at the time of
Inspection.
5.1.6. Prepare and obtain the proper required work permit prior to start work.
5.1.7. Locate and Identify the Tie-In point and put Tie-In number for its proper
Identification and prepare all required materials for the execution of the Tie-
In and ensure prior to start activities the lines (KRTJB2-1 & KRTJB2-2 of 24”-
P-0008-3CS1P1) shall be Isolated and Gas test has been performed.
5.1.8. Loosen the stud bolts of the flange joints and take out the existing breakup
spools (from the Tie-In points Q86-005 & Q87-007 which are connected
between Flow Control Valves (FV-0005 & FV-0006) and T-flange joint.
5.1.9. Cut and take out the existing flanges from the breakup spools of KRTJB2-1 &
KRTNB2-2 line #.24”-P-0018-3CS1P1 which are previously connected
towards T-flange joint.
5.1.10. After cutting the existing flanges and then cut & fabricate the existing spools
with reusing the same existing flanges as per the latest IFC drawings to
accommodate the Gate Valves for both the KRTJB2-1 & KRTJB2-2 of line
no.24”-P-0018-3CS1P1 to complete the flanged Tie-In #.Q86-005 & 007.
5.1.11. Fit-up and welding shall be done as per approved WPS by the approved JCC
holding qualified welders and welding operators.
5.1.12. After completion of welding, applicable NDT shall be performed as per the
drawing and line class specification.
5.1.13. After completion of required NDT, Hydro Test shall be performed for the
existing fabricated spools to check the integrity of the welded joints of the
flange.
5.1.14. All existing fabricated breakup spools shall pass visual inspection for
cleanliness any and all foreign materials shall be rid from the inside.
5.1.15. Fabrication QC documents shall have been completed and released for
installation & QC documents shall be made available upon Request for
verifications.
5.1.16. Complete the Tie-In #.Q86-005 & Q86-007 by Installing the Gate Valve and
Breakup spool as per the latest IFC drawing with new gaskets and final bolt
tightening (flange joint inspection) shall be perform as per approved bolt
tightening procedure.
5.1.17. Complete the Tie-in #.Q86-004, by installing the Ultrasonic Flow Meter-0001
with new gaskets in KRTJB2-1 line #.24”-P-0008-3CS1P1 as per the latest
IFC drawing and perform Bolt tightening (Flange joint Inspection) as per
approved bolt Tightening procedure.

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 UPGRADE GAS FLOW CAPACITY
BIN QURAYA EST.
(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

5.2. Fittings, Valves, Pipes, Nipples, shall be free from handling, or Fabrication,
Manufacturing Damages.
5.2.1. Verify the materials, type and class of Flanges against the Line class
specification Of the Header Pipe in SAES – L – 105, Table 1.
5.2.2. Verify the material, Type and class of Valves against the line class
specification of the header pipe as per SAES-L-105.
5.2.3. Raised contact of Flanges shall have as machined roughness of 3.2 –
6.4Micrometers, free from physical damages and shall not be coated.
5.2.4. The Bolts and Nuts assemblies shall pass inspection as to the following:
5.2.4.1. Material Specification/Stamp:
a. Bolt: ASTM A193
b. Nut: ASTM A194
c. Diameter: 1-½”
d. Length: 9-¼”
5.2.5. The Bolts and Nuts and washers for Flanges assemblies shall conform to
Piping class
Specified in the Tie-In Schedule / Packages, reference SAES-L-105 Table-1.
5.2.6. Refer to SAES-L-109 for Bolts and Nuts Specification according to the types
of Services.
5.2.7. Gasket materials for tie-in shall bear the following Information:
5.2.7.1. Material Specification / Stamp:
a. Type: Spiral Wound Gasket
b. Diameter: 24” X CL 300#
c. Material: Flexible Graphite Filler, 316 SS Winding, 30-½”
OD Outer Ring, CS Ring.
5.2.8. Gasket materials shall conform to Piping class specified in the Tie-In
schedule
Tie-in packages.
5.2.9. Refer to SAES-L-109-Gasket Specification.
5.3. The storage and handling of tie-in materials shall be in accordance with SAES-L-350
and 01-SAMSS-010.
5.3.1. All Piping end shall be kept covered to prevent the entry of foreign
materials.
5.3.2. Tie –In Flanged assemblies shall pass Inspection in accordance with SAIC-L-
2014, Inspection of Bolted Flanged Joint Assembly.
5.3.2.1. For general information, the following shall be made available
during the Inspection:
a. Line Class: 24”-P-0008-3CS1P1.
b. WT/SCH: 0.375”
c. Fluid Services: Crude Oil
d. Service Temperature: 170°F
5.3.3. Verify that there is no coat on flanges face, flange to flange ratings and pipe
Classification as per SAES-L-350.
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 UPGRADE GAS FLOW CAPACITY
BIN QURAYA EST.
(UGFC)
CONTRACT NO : 6600033800 PREPARATION DATE : 01 Mar 2015
BI NO : 10-00903 DOCUMENT NO & REVISION : UGFC-PQCP-049, REV: 01

5.3.4. Seating area on flanges face shall be free from damages, as per SAEP-351,
Attachment 2.
5.3.5. Flange alignment tolerances shall be as per SAES-L-350, rotation of flanges
shall not exceed ±2.4 mm. The tilt of a flange measured at the periphery
across any diameter shall not exceed 1.6 mm from the square position.
5.3.6. Flange Joint with spectacle plate alignment shall have tolerance as following:
A. Vertical Bolt offset: ± (2.4 + 30%) = ± 3.12 mm,
B. Horizontal Bolt offset: ± (2.4 + 30%) = ± 3.12 mm,
C. Rotational offset: ± (2.4 + 30%) =3.12 mm,
D. Combination of vertical and horizontal offset: ± 3. 2 mm,
5.3.7. Verify the Gasket compatibility with the flanges facing as per SAES-L-350,
Attachment 3 for gasket type selection.
A. Ensure flanges are free from any damages in the seating element
particularly.
B. Use no more than one gasket between mating surfaces of flanges.
C. Gasket shall pass inspection as per SAIC-L-2014, Section E.
5.3.8. Bolts and Nuts supplied for the flanges Joint shall be inspected in accordance
With SAIC-L-2014, Section F.
A. The shanks or threads on bolts and nuts shall bear no physical
damages.
B. Verify the identification markings and suitability to the service
Temperature, i.e. materials for process & General Service, Low. Temp.
Service, upper intermediate temperature services, sour services.
C. SAES-L-105, Line classification table shall be used to verify the Bolts
and Nuts Conformity with the material list.
D. Bolts shall extend completely through the nuts (Full thread
engagement).
E. The method of bolt tightening shall have been reviewed and approved
By Saudi Aramco representatives.
F. Documents the Bolts tightening activities using SATR-L-2001.
G. SATR-L-2011 shall be accomplished by the contractor.

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