Gow NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD RAS TANURA REFINERY CLEAN FUELS PROJECT CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION PROCEDURE CATEGORY QUALITY CONTROL DISCIPLINE PIPING TITLE DOCUMENT NUMBER PIPING FABRICATION AND ERECTION PROCEDURE ADW-TR-RTCF-QP-ME-001 REV-01 SUBCONTRACTOR DOCUMENT REVIEW STATUS (CONTRACTOR /COMPANY) STATUS STAnes | CODE DESCRIPTION Oo 1 | approven wirHour comments i} 2 CONDITIONAL APPROVED, WORK MAY PROCEED-INCORPORATE AND RESUBMIT Oo 3. | REJECTED, Revise AND RESUBMIT (e} 4 REVIEW NOT REQUIRED, INFORMATION ONLY, WORK MAY PROCEED oO 5 | vevereD/ canceLteo REVIEWED BY TECNICAS REUNIDAS: APPROVED BY SAUDI ARAMCO NAME: NAME; SIGN: SIGN: DATE: DATE: WA a] pe] ox | oworcss | srrement | nosmpon | wovgliaon ima/nneu © | erocras | remem | pstnunan | mov.nnay | mannaricw Rev. 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CO. LTD ti | ew RAS TANURA REFINERY CLEAN FUELS PROJECT , i ai : gout oj CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION Sons 5 54 52 53. 54. 55. 56. 57. 58. 6. 61 6.2 63. 64. i 7A 72. 73. 74, 75. 76. 77. 8. 84 82. 83. 9. TABLE OF CONTENT SCOPE . PURPOSE ........ REFERENCE..... DEFINITION. RESPONSIBILITY... PROJECT MANAGER CONSTRUCTION MANAGER...... CONSTRUCTION SUPERINTENDENT FIELD ENGINEER. CONSTRUCTION SUPERVISOR QC MANAGER....... QA/QC INSPECTOR. HSE TEAM....., PROCEDURE GENERAL PRODUCTS AND MATERIALS...... MATERIAL RECEIVING, STORING AND DELIVERY MATERIAL TRACEABILITY ....... PRE-FABRICATION CHECKLIST FOR PRE-FABRICATION OF PIPING. ISOMETRIC MARK-UP .. CUTTING AND BEVELING......... FIT- UP AND TACK WELDING ... BRANCH CONNECTIONS FLANGE JOINTS...... CLEANING OF SPOOLS PIPING ERECTION GENERAL... PIPE SUPPORTS..... INSTALLATION OF UNDERGROUND PIPES... INSPECTION REQUIREMENTS. ae ADW-TR-RTOF-QP-ME-001 REV-01 Page 2 of 24NAWAF MATAR AL-ADWANI & TRADING, CONT. CO. LTD Gecmene RAS TANURA REFINERY CLEAN FUELS PROJECT CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION 94 9.2. 93. 9.4, 95. 9.6. 10. 10.1. 10.2. 10.3. 10.4. 10.5. "1 12. 13. 14, ADW-AR-RTCF- DIMENSIONAL CHECK .... IDENTIFICATION AND MARKING WELDING INSPECTION... PRE-HEATING «0. occcsssestnentsenese NON DESTRUCTIVE TESTING (NDT) GALVANIZING, PAINTING AND COATING GENERAL cece. ABRASIVE BLAST CLEANING. GALVANIZING...... PAINTING AND COATING REPAIR OF DEFECTS OR DAMAGES PRESSURE TESTING FLUSHING....... REINSTATEMENT... INSPECTION AND TEST PLANS. -E.001 REV-01 Page 3 024e~ NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD RAS TANURA REFINERY CLEAN FUELS PROJECT CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION 4; SCOPE This document covers the sequence of activities for Fabrication, Erection and Installation procedure for Metallic Piping systems and to ensure that the above activities are in compliance with the Contractual requirements for Ras Tanura Refinery clean fuels Project. PURPOSE, The purpose of this procedure is to define the controls to be applied on all piping fabrication and erection activities (site) to complete the job as per company quality standards and specifications REFERENCE The following documents shall form a part of this procedure in the manner extend indicated herein ‘Schedule "Q" SAES -L-350 SAES-L-310 SAES -L-150 SAES-L-105 SAES-W-011 SAES-A-004 SAES-A-007 01-SAMSS-017 ‘SAEP-351 ASME Sec. IX ASME B31.3 ASME B31.4 ASME B16.11 ASME Sec. II Part C AWS D1. ASME B 16.5 ADW-TR-RTCF-OP-ME-001 REV-01 Quality Requirements Construction of Plant Piping Design of Plant Piping Pressure Testing of Plant Piping and Pipelines Pi Welding Requirements for On Plot Piping ig Material Specifications General Requirements for Pressure Testing Hydrostatic Testing Fluid Lay-up Procedure ‘Auxiliary piping for mechanical equipment Bolted Flange Joint Assembly Welding and Brazing Qualifications Process Piping Pipe Line Transportation systems for liquid hydrocarbons and other liquids. Forged Fittings, Socket- Welding and Threaded Specifications for Welding Rods, Electrodes, and Filler Metals Structural Welding Code-Stee! Pipe Flanges and Flanged Fittings Page 4 of 4CONTRACT No.: 10100-25330 NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD ti Seeman RAS TANURA REFINERY CLEAN FUELS PROJECT i a pga oy! | PIPING FABRICATION AND ERECTION 1\ API-1104 12-SAMSS-005 SAEP-1151 SA175 SAES-L-450 SAES-L-410 SAES-H-002 SAES-A-005 01 SAMMS-010 02 SAMMS SAES-W-016 SAEP-1160 SAEP-352 SAEP-1142 SAEP-1143 SAEP-1144 SAEP-1145 SAES-H-001 ASTM-A-123 4. DEFINITION COMPANY CONTRACTOR SUB-CONTRACTOR SAPMT saiT PoP ASME HT RFI MPT NDT PMI ADWE-TR-RTCE-OP-ME-001 REV-01 Welding of pipe lines and related facilities. Marking of Metallic Products Inspection Requirement for Contractor Procured Material and Equipment Documentation Requirements/ITP Requirements/Level of Inspection Construction of on Land and near shore pipe lines Design of pipe lines. Internal and External coating for steel pipe lines and piping Safety Instruction sheet Safety Instruction sheet for piping and pipe line Piping Material Specifications Material Selection and piping system Fabricated Steel Piping Butt Welding Pipe Fittings Welding of Special Corrosion Resistant Material Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Project. Welding Procedure Review and Approval Qualification of Non-SaudiAramco NDT Personnel Radiographic Examination Magnetic Particle Examination Liquid Penetrant Examination Coating selection and application requirements for industrial plants and equipment's. ‘Standard specification for Zinc (Hot-Dip Galvanized) Coating on Iron and steel Products ‘SAUDI ARAMCO TECNICAS REUNIDAS SAUDIA AL-ADWANI CO. LTD Saudi Aramco Project Management Team Site Quality Inspection Team Project Quality Plan American Society of Mechanical Engineers Hardness Testing Request for Inspection ‘Magnetic Particle Testing Nondestructive Testing Positive Material Identification Page 8 of 24NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD ti Bumre RAS TANURA REFINERY CLEAN FUELS PROJECT i CONTRACT No.: 10100-25330 ae PIPING FABRICATION AND ERECTION PT - Penetrant Testing PWHT - Post-Weld Heat Treatment RT 2 Radiographic Testing UT Ultrasonic Testing Wes - Welding Procedure Specification POR - Procedure Qualification Records SAIC - ‘Saudi Aramco Inspection Checklist SATR - Saudi Aramco Test report SATIP - Saudi Aramco Typical Inspection Plan SAES - ‘Saudi Aramco Engineering Standards SAEP_ - Saudi Aramco Engineering Procedures SAMMS _ ‘Saudi Aramco Material System Specification LBE : Log Book Entry NCR - Non-Conformance Reports RESPONSIBILITY 5.1. PROJECT MANAGER Responsible for overall project construction package completion as per schedule with proper safety and quality 5.2. CONSTRUCTION MANAGER Responsible for overall site management, execution of quality procedures that meets project specification and project requirements along with client satisfaction. Establishment of construction organization, monitor job quality and overall project management. 5.3. CONSTRUCTION SUPERINTENDENT ‘Shall be responsible for the execution of this procedure, monitoring and control of activities Pertaining to the pre-fabrication and installation of piping and its components, compliance with Project quality requirements and HSE procedure. 5.4, FIELD ENGINEER Field engineering inspection and supervision in the area of piping works and ensuring implementation and adherence to project specifications, procedures and HSE policies. Shall provide technical support to the operation of piping works and ensure that piping fabrication and erection, inspection and testing meet the project specification ensuring with latest IFC, continuously check and review the changes status during the work. ADW-TR-RTCF-OP-ME-001 REV.01 Page 6 of 24NAWAF MATAR AL-ADWANI & TRADING, CONT. CO. LTD Pesan RAS TANURA REFINERY CLEAN FUELS PROJECT CONTRACT No.: 10100-25330 i PIPING FABRICATION AND ERECTION 55. 56. Av 58. ae CONSTRUCTION SUPERVISOR Shall ensure that all site activities are performed in environmentally safe and responsible manner accordance with HSE and follow-up all safety procedures, permit to work, etc. ‘Shall supervise piping works and ensure the compliance with established construction schedule and project requirements as per applicable specifications and standards. QC MANAGER Responsible to report any deficiencies in the quality of work to the Project Manager, Preparation and maintenance of Quality Plan, internal Audits Schedule ,Implementation of Quality Audits with respect to Company Procedures, Quality Plan and schedule Q Attachment V. Periodically, Confirming that corrective action have been taken for NCR and LBE in consultation with Project manager, evaluate and monitoring the effectiveness of the project Quality Plan and Quality system of suppliers and vendors within the Sub-contractors scope, Advising the Project manager regarding the appropriate preventive action following the occurrence of any non-conformity work, He has the authority to stop work in any area where discrepancies remain uncorrected. The QC Manager shall coordinate with the Field Engineering Group, Project Superintendent, QC Inspectors and subcontractors to ensure that the Method Statement | Inspection Test Plan (ITP) and procedures are properly implemented as per company specification, Quality Plan and schedule Q Attachment V, QA/QC SUPERVISOR Shall arrange and supervise all QC activities ensuring that all inspection are performs in timely ‘manner and documented. Before start activities tool box shall be conducted. QC WELDING INSPECTOR Shall be responsible for inspection and testing of all piping welding activities. He shall be responsible for welding consumable receiving inspection, fit up, weld visual, welding consumable issuance, and NDT witness. The welding report shall be prepared by welding inspector and submitted to TR and Saudi Aramco Inspector. Before starting activities tool box shall be conducted. He shall monitor welder rejection rate, welder progressive examination weekly. NDT COORDINATOR Shall coordinate with welding inspector and NDT service providers for executing the NDT. He shall correctly identify and verify the selected weld joints before offering to NDT service provider. He shall identify joints with warning tapes as per NDE control procedure for repair joints shall be done by same. He shall prepare weekly welding rejection rate, welder rejection rate etc. As Per the AOWE-TR-RTOF-OP-E-001 REV-O1 Page 7 of 24NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD ti GBemmems RAS TANURA REFINERY CLEAN FUELS PROJECT i pa CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION 6 5.1 5.4 ‘SAEP-1108. NDT coordinator shall endure that sport / percentage radiography joint are selected by TR inspector. 0. QA/QC PIPING INSPECTOR Shall be responsible for inspection during materials receiving, fabrication, installation and testing of ‘spools to ensure the procedures are being followed in order to ensure that quality standards being achieved as per Project procedures, requirements and specifications, responsible for maintenance of NDT records & Project QC documentation. As per SAEP-324 para 5 and Schedule Q. 4. HSE TEAM ‘Shall be responsible for the implementation of the HSE procedures before and during the ‘execution of Piping fabrication, Installation and Testing and responsible for check for any unsafe conditions on the working areas and liaise with field Supervisor ensuring that the work is carried ‘out as per approved Project safety plan and procedure. PROCEDURE 61 GENERAL + Ensure that the document/drawings received from the contractor bear the stamp "Issued for Construction” and are of latest revision. + The documents submitted/referred with this procedure shall be considered as an integral part of this procedure and shall be read in conjunction with the same. + The engineering drawings and documents received shall be clearly understood to find out the service, material specification, size, thickness, QA/QC requirements, pipe routing, quantity, and line Class, Safety Instruction Sheet (SIS) etc. + Make sure that all the Quality control and Pre-Construction requirements, approvals, and Preparations are done sufficiently in advance to start the construction activity as per the schedule to comply with Company requirements. + HOT WORK permit procedure and Operations instructions must be followed as per safety precautions documents. 6.2. PRODUCTS AND MATERIALS a. Proper HSE procedure and material handling procedure must be followed during material receiving, storing and delivery. b. All materials shall conform to the IFC drawing with relevant material specifications before receiving/ordering. ADW-TR-RTCF-OP-ME.001 REV.O1 Page 8 of 24NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD ti Gree jl RAS TANURA REFINERY CLEAN FUELS PROJECT i cl CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION 6.3. ©. Separate area shall be assigned for the storage of different piping materials, Pipes stored in ‘open area shall be resting on wooden sleepers and proper end protection/Covering, fittings, bolts, nuts, and gaskets shall be stored in shelved containers or wooden pallets. Storage and issue of piping materials shall be controlled as per material storage, protection, and preservation procedure. 4d. Handling and transportation of piping materials shall be done with utmost care to avoid any damage. €. QC inspector shall conduct visual inspections, check color code, material certificates or manufacturer's test reports (including size, wall thickness, rating, material code, heat no, quantity) based on applicable Inspection and test plans and checklists. MATERIAL RECEIVING, STORING AND DELIVERY The following procedure shall be followed for receiving, storing and delivery of all the materials, a) In addition, Sub-Contractor Material Control procedure, material Storage protection and preservation procedure shall be strictly implemented and monitored during all material receiving and handling locations. 'b) Material control supervisor shall be responsible for receive all materials and documents to the job site in good condition. Marking of all metallic products shall conform to 12- SAMSS-005, all materials and documents will be inspected immediately upon receipt by Sub-Contractor QC Inspector to determine that all items included in the Delivery note or bill of materials have been supplied, to assure that all documents has been received as per SA-175 and to check for any damage, ©) All materials shall be inspected by Sub-Contractor QC prior to issue for prefabrication activities. ) The receiving materials or equipment found defective or presenting non-conformance that shall be clearly marked, tagged and quarantined, the same shall be reported and returned to corresponding supplier or Contractor. ©) Material shall be stored at defined locations based on material classification. Carbon Steels, Alloyed Steels, Stainless Steels, non-ferrous material etc. Carbon steel and Stainless steel materials shall be segregated to prevent carbon contamination as per material control Procedure. f) Large-sized fittings, flanges and valves shall be stored on wooden pallets and no material is allowed to rest or store directly on ground. All small-sized fittings, flanges, valves and of gaskets shall be stored on racks or wooden pallets with proper identification. Q) All bolts, washers and nuts shall be stored and delivered in rigid, weatherproof containers or wooden pallets. h) Flanged openings shall be fitted with plywood covers or fitted PVC flange covers, threaded openings are to be closed with plugs or similar, pipe openings shall be cover with end cap or plastic cover to prevent accumulation of dust or foreign materials. i) Ensure the material is secured properly so that it does not fall, roll or move from its storage position. Pipes will be supported at bottom with wooden blocks at least at three points and choked with wedges. i) Materials stored in open areas will be barricaded and indicate the type of material and the ADWE-TR-RTCF-OP-ME-001 REV-01 Page 901 24| dou yt RAS TANURA REFINERY CLEAN FUELS PROJECT NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD th a pga Soh CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION E>E> E A 7 64. hazard it possesses, if any. ) Coated pipe shall be handled at all times in a manner that prevents damage to the pipe coating (shall not be rolled or dragged on the ground), beveled ends and to the coating and open end should be covered with polyethylene sheeting and in accordance with project specification (SAES-H-200). 1). Slings used for shifting materials shall be nylon or equivalent; stee! cables shall not be used. m)Each length of pipe shall be examined to make sure it is free from internal obstructions and shall be air blown to remove dust and sand immediately prior to erection or welding, 1n) Materials released for the specific Isometric drawing shall be used for the same and shall not be used for other Isometric drawing/location ©) Scrap materials shall send back to Lay down area with identification such as_ line number, heat no and material code, Scrap materials, Incoming materials awaiting Inspection, accepted materials and rejected materials shall be properly segregated ) Material shall be received, stored, and delivered strictly as material control procedure, and material preservation procedure. q) Cement lined and FBE coated pipes and fittings shall be stored in designated area. It shall be lifted with wide fabric or rubber covered sling and padding shall be used to prevent damage to lining or coating. Wire rope slings shall not be used. 1) During the storage of the coated pipes shall be placed at least 150mm of the ground on either Tock free sand berms covered with polyethylene sheeting or on padded skids spaced and leveled so that the pipes are supported without damaging the coating 's) Stainless steel spools shall be marked with low chloride marker and to be tied with SS tie wires. ) Stainless steel spool handling, Transportation and preservation shall be as per approved Material handling storage and preservation procedure. MATERIAL TRACEABILITY ‘@) Project identification, heat number and Drawing number shall be clearly marked on each plate, pipe and nozzle item by the Material Controller / Storekeeper. b) QC personnel shall monitor the transferring of heat number for all materials. ©) To prevent loss of traceability during paint / coating process, QC personnel shall make sure that the identification number is transferred to the QC recordsiinside the pipe prior to blasting 4) Piece marks and weld identification number shall be marked on each pipe / plate by suitable paint marker which shall be compatible with the base material to be marked and recorded on the relevant documents. €) Stainless steel spools shall be marked with low chloride marker 1) Color-coding shall be applied for easy identification to permit quick material handling / ‘segregation and visual check / monitoring during construction. PRE-FABRICATION TA CHECKLIST FOR PRE-FABRICATION OF PIPING ) Approval of Method Statement, Procedures, Quality Plan and ITP. ADW-TR-RTCF-OP-E-001 REV.O1 Page 10 ot24| NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD Geman RAS TANURA REFINERY CLEAN FUELS PROJECT CONTRACT No.: 10100-25330 PIPING FABRICATION AND ERECTION 72. 73, b) Approval of WPS covering all the material specifications. ) Approval of Welders and valid JCC available. 4) All the required Engineering drawings and documents are received in time. all material for production shall be clearly identified and permanently marked with material specification, grade and heat number to ensure traceability ¢) All personnel and procedures for NDT are approved, f) Weld mapping completed and available for inspection, weld joints shall be marked and clearly identified on weld map and in the field. g) All tools, equipment and temporary items like pipe stands; pipe clamps etc. are ready in sufficient quantities. h) Consumables shall be in sufficient quantities as per the WPS, and are inspected. i) Welding data base ready prior start of welding activities i) Handling and storage and conditioning of consumables is controlled and documented as per SAES-W-011 Attachment 1 & 2. k) Shop fabrication area for each type of material identified and marked. |) The checklist used for pre-fabrication inspection shall conform to SAIC-W-2005 and SATR-W- 2006 ISOMETRIC MARK-UP a) All lines shall be clearly marked to easily identify the service, line designation number, size, class and specification, b) The weld map shall be unique and separate for each line, system, and component or assembly number and available. ©) Straight run of pipe shall contain the minimum number of welds. The use of off-cuts in straight tun shall be avoided. 4) Piping connecting to the rotating equipment nozzles and its connecting points shall be field measured and fabricated to avoid external loading on the equipment connection. €) The minimum distance between parallel Butt welds shall be 20mm or three times the wall thickness of the joint, whichever is greatest. 1) Weld numbering methodology shall contain: a sequential number, a repair sequence number, and it shall be as per company specification 9) Length, height and width of the spools shall be within the limits of road transport and erection Possibility, unless specifically requested CUTTING AND BEVELING 2) All pipes and fittings shall be cleaned before prefabrication by air blowing. b) Proper Safety procedure shall follow before starting the job. ©) Marking should be done as per Isometric spool number before start cutting, 4) Cutting of pipes, fittings and edge preparation shall be as per the IFC drawing and WPS. ©) Pipes shall cut using Oxy-acetylene cutting or plasma as per project requirement. Flame cutting of Stainless Steel is not allowed. The edge cleaning and beveling shall be done using abrasive grinding disc. When cut is done by Oxy or plasma the surface shall be thoroughly cleaned 25mm ADW-TR-RTCF-QP-ME-001 REV-01 Page 11 of 24NAWAF MATTAR AL-ADWANI & TRADING, CONT.CO. LTD | ti GBeaene RAS TANURA REFINERY CLEAN FUELS PROJECT =| i ae a coinage coc ay PIPING FABRICATION AND ERECTION with following methods. ‘ CARBON STEEL (C.S) Gas cutting, Machining or grinding methods shall be used. After gas cutting, oxides shall be ‘smoothened I removed by chipping and grinding. ALLOY STEEL Gas cutting, Machining or grinding methods shall be used. After gas cutting, machining or grinding shall be carried out on the cut surface. # STAINLESS STEELS (S.S), NICKEL ALLOYS Machining or grinding methods shall be used. After cutting, cut surface shall be machined or ground smooth, ) The edges to be welded shall be prepared to meet the joint design requirements by any of the following method recommended: 9) The checklist used for pre-fabrication inspection shall conform to SAIC-W-2005 and SATR-W- 2006 h) Where, spectacle plate is required by the ISO drawing, the fabricator shall drill a tap and install jack screw for flanges as per IFC Drawings. ) Heat numbers has to be transferred to pipes before cutting remaining material must be kept allocated locations with all marked specifications. i) Welding ends shall be protected against damage during handling and shipment by means of a securely fastened bevel protector or plastic cap cover. 7.4. FIT-UP AND TACK WELDING ) Fit-up assembly and joint alignment shall be carried out, by using clamps or any other approved method. All the required pipe holding work benches, assembling brackets, 'U' bolts etc. would be made to suit the pipe sizes and material. ») Internal misalignment of butt joints shall not exceed 1.5 mm. ©) All welding ends shall be beveled with and angle of 35 degree, +2.5 degrees, and a root face of 1.6 +8mm and shall confirm with applicable WPS. 4) Fittings that are re-cut or re-beveled shall have the cut surface examined for laminations before welding. The NDT method to be used shall be determined by company. €) All tack welds shall be performed by qualified welders with the same care, materials, electrodes, minimum pre heat, and procedures that are used for the permanent welds. ) For butt welds a uniform root gap shall be maintained as per approved WPS, 9) Lateral transition of branches and connections from centerline of the run shall not exceed +#1.5mm h) For all socket weld joints the pipe end shall be free from cutting burrs, all socket welds shall be at least two pass weld. ) Tack welds shall be sufficient size to maintain joint alignment. The recommended tack thickness is 3.2 to 4.8 mm and length is 12.5 mm to 25.4 mm and the maximum number of tack welds is pipe diameter of 101.6 mm or less three equally spaced tacks, and diameter is more ADV/TR-RTCF-OP-ME-001 REV-01 Page 12.0124