Document No.

Corporate Academy Dhahran CRCC-SACAP-SP-0

B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

Lay-Up Procedure For Carbon Steel

Document Control
Document Information:
Document ID CRCC-SACAP-SP-013
Issued Date 03-03-2024

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

Document History:
Revision
Issued Date Document History
No.
00 03-03-2024 First Issue for Review and Approval

Action Position/Role Name Signature Date

Prepared By Welding QC Sureshkumar 03-03-2024

Construction
Reviewed By Manager
Moez Osman 03-03-2024

Reviewed By HSE Manager Jack Apas 03-03-2024

Approved By Project QA Manager Malik Rafee Ahmed 03-03-2024

Approved By Project Manager Ahmed Elsayed 03-03-2024

Document Review Structure:

Document Distribution Register:

Controlled Date of Issue Name of Recipient Position/Role

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

Copy Ref.
No.
01 Project Manager

02 Construction Manager

03 Project QA Manager

04 Engineering Manager
05 HSE Manager

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

Table of Contents

1. SCOPE………………………………………………………………………………… 05
2. PURPOSE.............................................................................. 05
3. REFERENCES……………………………………………………………………….. 05
4. RESPONSIBILITIES………………………………………………………………. 06
5. INTRODUCTION…………………………………………………………………..07
6. MATERIALS OF CONSTRUCTION CATEGORIES……..……………… 07
7. LAY-UP REQUIREMENTS ……………………………………………………. 07
8. LAY-UP TYPES ……………………………………………………………….….. 09
9. HEALTH & SAFETY …………………………………………………………….. 09
10. ATTACHMENTS ……………………………………………………………….. 09

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

1.SCOPE:
This procedure defines here to prevent the system corrosion due to oxygen(air) ingress and to prevent
microbially induced corrosion. Lay -up procedure shall prevent oxygen ingress.
2. PURPOSE:
The purpose of this procedure is to provide guidelines to conduct Lay-up of piping according with SAES-A-007
(Hydrostatic Testing Fluids and Lay-up Procedures) in the CRCC for Corporate academy Dhahran project.

3. REFERENCES
All the Aramco standards cutoff date for corporate academy Dhahran project is October 2020.
All the international standards used for this project are the latest edition.
 IFC Drawings & Project Specification
 Mandatory Saudi Aramco Engineering Requirements (MSAER)
 HE-035524 Saudi Aramco construction Safety Manual
 SAEP – 381 : Project Quality Issues Escalation Process
 SAES-W-011 : Welding requirements for On-Plot-Piping.
 SAES-L-350 : Construction of Plant Piping
 SAES-L-310 : Design of Plant Piping
 SATIP-W-011-01 : Welding of On-Plot-Piping.
 ASME B31.3 : Process Piping
 ASME B31.4 : Pipeline Transportation System for Liquids and Slurries.
 ASME B31.8 : Gas Transmission and Distribution Piping Systems.
 ASME SEX II C : Welding Rods, Electrodes, and Filler Metals.
 ASME SEC IX : Welding & Brazing Qualifications.
 SAES-A-004 : General Requirements for Pressure Testing
 SAES-A-007 : Hydrostatic Testing Fluids and Lay-up Procedures
 SATIP-A-004-02 : Hydrostatic Testing of On-plot Piping

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

4. RESPONSIBILITIES:
4.1 Construction Manager:
 Responsible to Provide site teams with appropriate resources to ensure that works are done
in.
accordance with the project quality and HSE requirements. Responsible for the overall site
work management.

4.2 QA Manager:
 It is the responsibility of QA manager for the review and approval of method statement /
procedure of welding work.
 It is the responsibility of QA manager to ensure that the Quality of work is in accordance to
approved project quality plan.
 It is the responsibility of QA manager to ensure that the company QM has been effectively
enforced in the project.

4.3 QC Manager:
 Responsible for evaluating and monitoring the effectiveness of Project quality plan and Quality
system of Suppliers & vendor within the contractor scope. Coordinate, monitor and follow up
the inspection of all materials & equipment. Plan and coordinate with his site quality team the
inspection and testing of each item.

4.4 Foreman/Supervisor:

 The project team of experienced supervisors and foremen will ensure the quality of the lay-up
work carried out and shall also ensure that it is in accordance with the latest approved shop
drawings issued for installation and according to instructions received from the site engineer.
 He will provide his subordinates (charge hand and conduit fitters) adequate information to
carry out their duties.
 He will ensure that he has adequate resources of machinery, labor, and materials to carry out
all the activities efficiently and to discuss with the site Engineer.
 He will ensure a safe and clean working environment to enforce safe working habit.

4.5 QC Inspector:
 Shall be responsible for assurance that methods and materials are both in conformance with
the specification.

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

5. INTRODUCTION
Lay-up of piping must be performed immediately during dewatering in order to control corrosion
and microbiological damage during and after hydro test and pre- commissioning cleaning
activities.

6. MATERIALS OF CONSTRUCTION CATEGORIES

In order to ensure adherence to this standard’s requirements, materials of construction are
categorized into the following to align water quality, chemical treatment and lay-up requirements;
refer to attachment 1

7. LAY-UP REQUIREMENTS (as per SAES-A-007)

 Hydrostatic testing and lay-up procedures shall contain safe guards to prevent oxygen ingress
except as specifically allowed in this standard.

1. The introduction of hydrostatic test water shall be properly planned and scheduled as close as
possible to the equipment and/or system start-up date. Partial or complete refilling of the
system counts as continuous, cumulative time.
2. Assets shall be laid-up per section 5 if water contact time exceeds the limits set in Table 1. This is
regardless of the purpose behind water usage, e.g. flushing, cleaning, etc.
3. Table 1 – Maximum Water Contact Time Limits

4. Once assets have been laid up, lay-up shall be maintained until preparing for start-up activities.
5. Table 2 outlines the recommended, acceptable and prohibited lay-up methods for pressure
equipment, piping and pipelines. Refer to SAEP-43 for lay-up methods’ application.

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

Table 2 – Lay-up Methods for Pressure Vessels, Piping and Pipelines

6. For Materials Category I, all lay-up methods are acceptable. Ambient lay-up can be used when all
below conditions are met:
6.1 Water is drained from all low points to ensure it is completely removed.
6.2 Corrosion allowance is adequate, and pitting can be tolerated, if it occurs.
6.3 Rust deposits can be tolerated during operations, e.g. for cases where there is no strict product
specifications and where Black Powder is not an operational concern.
7. For pipelines and piping, it is highly recommended to remove valves prior to hydrostatic testing
especially type 400-series stainless steel trimmed valves since they are highly prone to corrosion
after hydrostatic testing. Valve cavities will be difficult to dry out completely. If these valves
cannot be removed, then ambient lay-up shall be prohibited.

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

8. LAY-UP TYPES:
Types of lay-ups are listed below.

1. Wet Lay-up
2. Dry lay-up
3. Inert Gas Lay-up
4. Ambient Lay-up
As mentioned with reference to Attachment #1, Material category – (I) is used as material in the scope of
complete project, hence ambient layup is to be followed as per procedure, other methods are not preferred,
Ambient Lay-up requirement
 Remove all water from the system/hydro-test, and cleaning package.
 Blow the line with air until there is no traces of water inside the line.
 Close the system/Hydro-test, and cleaning package with metallic blinds or high impact plastic
wedge or wood covers or plastic film may be used on flanges providing that an impervious
membrane is placed between the wood and greased flange face to prevent entry of dust
and/or water.
 Ambient layup to be applied to carbon steel pipe.
 Plant piping must be laid-up after hydrostatic testing unless it can be insured that it will be
returned to service within 30 days from the first introduction of hydro test water to the
system.

9. HEALTH & SAFETY:

In addition to the Project Safety Plan the following points are followed:

a. Personnel shall wear gloves, safety boot/shoes and safety helmet. When required, safety
harnesses shall be worn and attached to a secure point when higher level work is being
undertaken.

b. All activities shall be performed under the supervision of the safety supervisor and shall
comply with the approved Job Hazard Analysis (JHA).

10. ATTACHMENTS:
Attachment #1 Material Categories and Sub-Categories

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

Attachment #1 Material Categories and Sub-Categories

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 Document No.
Corporate Academy Dhahran CRCC-SACAP-SP-0
B.I./J.O. No: 10-02403-0002 Contract No: 6601000138 Rev. 00

Lay-Up Procedure For Carbon Steel Date: 03-03-2024

________________________End of Document_____________________________

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