Document No.

Corporate Academy Dhahran CRCC-SACAP-SP-0

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

Special Procedure For Tie-In Activity Date: 24-04-2024

Special Procedure For Tie-In Activity

Document Control
Document Information:
Document ID CRCC-SACAP-SP-00
Issued Date 24-04-2024
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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

Special Procedure For Tie-In Activity Date: 24-04-2024

Document History:
Revision
Issued Date Document History
No.
00 24-04-2024 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

Special Procedure For Tie-In Activity Date: 24-04-2024

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

Special Procedure For Tie-In Activity Date: 24-04-2024

Table of Contents

1. SCOPE………………………………………………………………………………… 05
2. PURPOSE.............................................................................. 05
3.REFERENCES……………………………………………………………………….. 05
4. RESPONSIBILITIES……………………………………………………………….. 06
5. PROCEDURE ………………………………………………………………………. 07
6. SAFETY ………………………………………………………………………………. 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

Special Procedure For Tie-In Activity Date: 24-04-2024

1.SCOPE:
The scope of work includes the following activity: The proposed tie-in involves connecting two locations
by welding a 12-inch diameter carbon steel pipe to the existing network of 24-inch diameter cement-
lined carbon steel pipe for the raw water line near the Dana Gate valve at CRCC for the Corporate
Academy Dhahran project. This is in accordance with IFC drawing numbers HA-021008-001 and HA-
021761-002.
2. PURPOSE:
This procedure covers the Tie in by welding 12 Inch Dia Carbon Steel pipe to the Existing network of 24
Inch Dia Cement Lining Carbon Steel pipe for Raw water line on 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 – 1160 : Tracking and Reporting of Welding, NDT, and Pressure Testing for Capital
Projects.
 SAEP – 381 : Project Quality Issues Escalation Process
 SAES-W-011 : Welding requirements for On-Plot-Piping.
 SAES-W-012 : Welding Requirements for Pipelines
 SAES-W-016 : Welding of Special Corrosion-Resistant Materials
 SAES-L-350 : Construction of Plant Piping
 SAES-L-310 : Design of Plant Piping
 SATIP-W-011-01 : Welding of On-Plot-Piping.
 SATIP-W-012-01 : Welding of Pipeline
 SATIP-M-001-01 : Welding of Steel Structural
 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.
 AWS D1.1 : Structural Welding Code.
 ASME SEC VIII : Rules for Construction of Pressure Vessels

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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

Special Procedure For Tie-In Activity Date: 24-04-2024

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 Piping Fabrication Supervisors / Superintendent:

 Responsible for ensuring the safe and efficient working environment to monitor plant and
equipment requirements and to ensure that productivity and quality are maintained by their
subordinates. They are also responsible for ensuring that the proper material is being used
in addition to the correct welding consumable and the correct welding procedure.

4.5 QC Welding Inspector:

 Verify the adequate application of the requirements established in this document. Perform
all required inspection and release witness & hold points by signing of Quality Records /
Checklists. Responsible for all inspection activities as per SATIP, SAIC and all relevant
quality standards and procedures.

4.6 Engineering (Design):

 Developing a design and/ or calculations that is sound and meets all relevant Saudi
Aramco, Industry, International and National Codes and Standards.

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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

Special Procedure For Tie-In Activity Date: 24-04-2024

5 PROCEDURE:
5.1 General requirements:
 Perform material receiving inspection.
 Conduct toolbox meeting prior to start of TIE IN activities.
 Ensure Work Permit for the hot work activities.
 The tie in area shall be covered with a fire blanket.
 Ensure that all the relevant documents are approved prior to activity.
 Ensure that all the miscellaneous materials are available to be transported to the project site.
 WPS to be printed out at site welding area.
 Ensure to select good welders (with low repair rate) which are approved for the project.
 Ensure Welding Consumable to be used for tie in welding, are following Project Consumable
storage and handling Procedure requirements.

5.2 Mechanical isolation:

 The utility department will contact the mechanical isolation.

5.3 Cutting and assembly fit-up:

 All material identification by heat number, material specification, and color coding shall be
reassigned to cut out pieces for traceability on the assumption of many types of materials.
 Before cutting, the ultrasonic testing (UTT) will contact the header pipe for thickness
verification.
 Before cutting any branch connection outlet holes on the main header, from the Isometric
Drawing (ISO), The following components can be identified to prepare the cutting process for
branch connections with the aid of engineering calculations.

(1) Header pipe, the cutting shall be done as per specific calculation
(2) Run pipe, the cutting shall be done as same as the size of the cutting of header pipe.

 The cut hole, after grinding and finishing shall be examined for laminations before welding.
 The alignment, fit-up and tack welding activities shall be implemented after end preparation to
ensure achieving perfect pipe spool fabrication.
 After completion of pre-fabrication, the spool shall be cleaned and free from weld spatters, arc
strikes and foreign materials on outside and inside of pipes.

5.4 Pre-Welding and Fit-Up Inspection:

 Oil, Moisture, Rust, scale, sand, paint (except weldable primers for approved applications - refer
SAES-W-11 paragraph 7.4.4 for restrictions), metallic coatings (e.g., zinc), or other foreign
matter shall be removed from the weld surface at least 25 mm (1 in) of adjacent base metal
prior to welding, including any such coatings on temporary attachments or supports.

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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

Special Procedure For Tie-In Activity Date: 24-04-2024

 The fit up of the branch connection/split tee to the pipe shall be approve prior to welding.
 All weld joints preparation shall be marked near to the joint with permanent metal paint marker
for line number, component heat number, joint number, fit-up inspection signature, welder
number, visual inspection signature, and date of welding.
 Back welding may be used for any joint. Proper cleaning and, if necessary, grinding of the root
shall be done prior to back welding. Unless specified otherwise in the welding procedure, the
back welding shall be done using the same process and consumables as used for the fill passes.
 If a weld joint is wet or has surface moisture or condensation, it shall be dried by heating for
100 mm from the weld joint and shall be warm to the hand before welding unless a greater
preheating temperature is required as per SAES-W-11 para-12.3.
 The preheat temperature shall be established over a minimum distance of 75 mm on each side
of the weld as per SAES-W-11 para-12.5.
 If any grinding reduces the base metal thickness to less than the design minimum thickness, the
ground area shall be rewelded and ground flush with the original base metal surface or the
component shall be replaced. Rewelding shall not be done without prior approval from Aramco
Inspection as per SAES-W-11 para-11.8.
 Any temporary welded attachments or temporary tack welds shall be removed. Attachments
shall be cut off no closer than 3 mm to the base metal surface, prior to the required grinding as
per SAES-W-11 para-11.7.

5.5 In Process Weld Inspection:

 Conduct visual inspection for root pass.
 The direction of welding conforms to the WPS.
 Each weld pass is thoroughly cleaned, and all slag or other foreign matter removed before the
next pass is deposited as per SAES-W-11 para-11.4.1.
 Adjacent beads of a weld shall be staggered and not started in the same location as per SAES-W-
11 para-11.13.
 The maximum size of the electrodes shall be as per the applicable WPS.
 The maximum interpass temperature shall be as per the applicable WPS. (Unless specified
otherwise, the maximum interpass temperature shall be 177°C for P-No. 8, P No. 3X, and P-No.
4x materials and 315°C for P-1, P3, P-4, and P-5 steels. As per SAES-W-11 para 12.7)

5.6 Post Welding Visual Inspection:

 Ensure that all passes are done as part of post-welding visual inspection activities.
 Visual defects found in completed welds & at least 25mm wide on each side of the weld are
within the allowable weld imperfections.
 Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity,
uneven weld profiles, and undercut) shall be removed by grinding as per SAES-W-11 para-11.6.
 Welded toes shall be merged smoothly and rounded with no sharp undercuts.
 No crater defects, such as cracks, "suck-back," or shrinkage, are permitted.

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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

Special Procedure For Tie-In Activity Date: 24-04-2024

5.7 Installation of Reinforcement Pad:

 Reinforcing pad material shall be of the same pipe material unless otherwise approved in
writing by the SAPMT.
 Ensure all branch connection opening and any part or section of a reinforcement pad does not
cover the girth welds.
 Ensure that all mandatory NDTs are done for run and header pipe as per the project
requirements.
 Perform cutting and assembly fit-up as same as the size of the cutting of branch pipe.
 Plan soft grinding for run and herder pipe seam weld (if required)
 Apply the tack welding between reinforcement pad and branch (run and herder pipe) as part of
pre-welding and weld joint fit-up inspection activities.
 Ensure all weld pass are fully cleaned and all slag or other foreign matter are eliminated prior to
next pass is deposited.
 Ensure that complete weld and surrounding areas are cleaned from slag, foreign matter, and arc
spatter.
 Ensure that all passes are done as part of post-welding visual inspection activities.

5.8 NDT Requirements:

 All Branch connection welds will be visually inspected. For welds with a reinforcing pad the weld
between the branch and the header shall be inspected prior to installing the reinforcing pad and
again after installing the reinforcing pad.
 All lateral branch connections shall be inspected by RT/UT.
 All repair welding shall be implemented according to SAES-W-011 and approved WPS.
 After installation of the reinforcing pad, Liquid Penetrant Test (PT) shall be performed for final
welding verification uneven joint configuration.

6 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).

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