SAUDICO Pipe Fabrication Shop Approval Checklist

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2012) Rev 6 31-Mar-12
SAIC NUMBER DATE APPROVED DISCIPLINE

SAUDI ARAMCO INSPECTION CHECKLIST
Review & Approve Piping Fabrication Shop
SAIC- L-2031 30-Apr-13
(Guide - Assure Successful Project Start-up)
PROJECT TITLE WBS/BI/JO NUMBER CONTRACTOR/SUBCONTRACTOR
EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM
LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY
K. Raja Roa RFI No. REQUESTED INSPECTION DATE
ITEM
ACCEPTANCE CRITERIA REFERENCE Yes No N/A Comments
No.
1. Contractor informs Company when a Subcontractor (or his own)

fabrication shop (facilities, equipment & associated storage areas) are
ready for Company approval. Notification is prior to start of any Use this guide
production work per Sch. Q notification (2 weeks minimum). on interviewing
2. Contractor Quality uses this checklist & any of his own before Project Quality
Company Inspection audits new shops for SA SHOP APPROVAL. QA/QC Mgrs for
Note 3. "Shop" is an indoor/outddor fabrication facility approved by SA Prime
As Listed
1-5 Inspection (SAES-W-011, Sect 17.6) that follows standard industry Contractor &
fabrication practice. 12-SAMSS-007 refers to AWS D1.1. See also Subcontractor
standard practice referenced as Piping Fab Institute (PFI) & others. for quality start
4. Checklist identifies procedures, personnel, facilities, equipment & on major
storage including necessary controls for quality on SA Projects to assure projects
successful project start-up meeting quality reqmts.
5. SA can approve new shops in stages with controls in place.
A Special Process Procedures & Controls (For Shop Start-up) STAGE 1
Special Process Procedures were submitted 30 days prior to the start of

A1 Sch. Q, Att. V,
any work (operations) at fab shop as follows:
Special Process Procedure Revision Approval is received BEFORE
A2 Sch. Q, Att. V,
starting production work (operations) at new shop.
Welding Engineer (Contractor) is available for WPS package
CSD has the six-
review/approval before "30 days Prior" submission deadline SCH. Q, Att. VI,
A3 week policy on
• SA Approved Engineer is at site (6-8 weeks before shop kick-off) Table 2
WPS returns
• Engineer can expedite WPS revisions that avoid work start delay.
Welding Procedures Package (WPS) per SAES-W-011 Sect 7. A) Piping
WPS packages were submitted 30 days before work.
• CSD has returned Status 1 or Status 2 cover sheets for all WPS
Sch. Q, Att. V, &
A4 • Complete list of WPS is available in timely manner (no work delays)
IV
B) Structural procedure package to Project Inspection early
• Use AWS D1.1 Prequalified welding procedures
• Maintain list of procedures/status at site
Welding Special Process Procedures & Controls are revised & approved
(Sch. Q, Att. V, BEFORE work starts): A) Gap
Control for socket welds (meets code as revised) B) Seal
welding threads (Meets SAES-L-110 & code as revised)
C) Weld Consummable Control (Store, Issue, Reuse, Monitor)
Sch. Q, Att. V, &
A5 D) Welder Tracking (Qualification, WPS monitoring, retraining, etc) As Applicable
IV
E) Heat input measurement & WPS monitoring (pipe welding)
F) Pipe weld repair (weld defect repair, buttering, base metals)
G) Pipe welding related (Bevelling, joint & surface prep, preheat)
H) Repad Installation, Bending & Forming (pipe bends, ovality)
i) Structural Welding related (splicing, weld repair, prep, etc)
Page 1 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Welding Procedure Qualifications (for new shops):

A) Procedure Qualification Records (PQRs) are prepared/submitted on
SA Forms (Attachment A).
B) Weld and Line Designation Table ("Weld Table") is submitted along
with PQR documents (Attachment B) & provides a listing of materials,
A6 SCH. Q, Att. IV,
thickness, & weld joint types (individual line designation).
C) Hardness Testing is per SASD AB-036386 (mandatory)
D) Ferrite measurements per AWS A4.2 (as applicable).
E) Weld maps & tables are detailed & attached
F) Originals of all test records, mill certs, etc., are available to SA.
Never assume CSD previously approved WPS are valid. Check Weld &
Line Description Table details:
A) Verify that service considerations are identical
SAES-W-011,
A7 B) ORIGINAL CSD Cover Sheet listing status/restrictions is available
Section 7
C) Groove Weld procedures do not cover socket welds & fillets
Additional sketch or clear field instruction notes for QC & welders is
needed for socket & fillet welds (size, # passes,etc)
WPS Drawing Details (CSD common revisions):

A) Branch Connection Drawings are detailed to show applications
B) Weld size & prep depth shown (Drawings/Notes). Round up mm.
C) Single V-Groove Drawings reflect the following Notes:
• Maximum value for “t”
• Maximum weld metal deposit value (GTAW, SMAW, etc)
D) Fillet Weld Notes provide clear instruction to welders & QC:
A8 Sch. Q, Att. IV
• Minimum size (full fillet) or “a min” for seal welds/shims
• Detail/note integral acute angle attachments (dummy leg, bracing)
E) Socket Weld Notes provide clear instruction to welders & QC:
• Minimum number of passes (2), fillet size, shape, contour
F) Seal Weld Notes provide clear instruction to welders & QC:
• Process, sequence, shape, "no exposed threads" & NDT (MT/PT)
Ensure documents are not returned unapproved by CSD
WPS Miscellaneous details (CSD common revisions):

A) SMAW & GTAW diameter limits per SAES-W-011 are correct
B) Back purge rate notes (O2 level below 1% verified by analyzer)
C) Galvanize welding (sch. 80+) has special prep & test procedure.
D) Heat input limit range calcs are closely checked & correct
E) ER-70S6 is not utilized (GTAW). Use ER-70S-2, 3 (NACE matl's).
A9 Sch. Q, Att IV
F) E-7018-1 (increased manganese) is specified for SMAW welds when
Low Temperature applications are required at the Fab Shop.
G) PQR Hardness Values do not exceed 200 BHN (NACE WPS)
H) Travel speed RANGES are specified. Maximum Oscillations (3 x wire
diameter) are verified to be within correct range (travel speed)
i) Preheat Tables provide clear field instruction (SAES-W-011, etc)
Page 2 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Check WPS Weld & Line Description Table for misc. details:
A) Identify lines that require Charpy Impact, PHWT & BHT (values)
B) Cement lined pipe welding requires special CSD considerations
C) Base metal thickness range requires backing (butts below 1/8") SAES-W-011,
A10
D) 100% PT & RT for GTAW butt welds below 1/8” or 3.2mm Section 7
E) A separate procedure requiring surface preparation details and
coating repair must be submitted for welding galvanized piping.
F) Piping class 12LE0U1 (FBE-lined piping) requires similar treatment
NDT/NDE Technique procedures have been Dhahran approved

A11 • Cover letter approval from NDTU Dhahran has been received Sch. Q, Att.IV,
• Revision requests and changes from NDTU Dhahran are complete
NDT/NDE CONTROL procedures are issued and clear for all

Attachment 1
• NDT controls by prime contractor assure adequate supervison
Guide for
• Critical elements in Control procedure maintain NDT integrity
A12 Sch. Q, Att. IV, approval of NDT
Guide for PID Review (NDT CONTROLS) Know the
control
difference between NDT "Technique" Procedure & and NDT "Control"
Procedures
Procedure. Control is mandated by Q.
PMI procedures & Equipment (Package) is CSD approved

A13 • Equipment for testing is at site or readily available Sch. Q, Att. IV,
• Material receiving checks & system of testing identification known
Coating Package (application/procedures) has been approved
• Equipment & Set-up (See SAES-H-100 Checklists A, B, C, D)
A14 Sch. Q, Att. IV,
• Location (Site) & Operations must be approved by Saudi Aramco
• Coating crews (blaster, painter, & supervisor) have SA cards.
Heat Treatment Procedure & Equipment Package is CSD approved

(similar to Welding per SAES-W-011, Section 13):
A15 • Cover letter approval from CSD has been received Sch. Q, Att. IV,
• Revision request/changes from CSD have been addressed
• CSD has returned Status 1 or Status 2 cover sheets for WPS
Heat Treatment (associated process) requirements:

A) Prior to work (2 wks), contractor or fabricator prepares a table listing
each joint or component for heat treatment (to SA Inspection)
B) Table (each joint or component) has location, dwg number, size, wall
SAES-W-011,
A16 thickness, material, heating rate, cooling rate, soak temp/time.
Section 13 & 14
C) Brinnell Hardness Test procedure is NACE RP 0472, App. A
• Brinnell Equipment Kit is available at site for testing
• Contractor has good supply of "Certified" test bars (194, 200+)
• Contractor has certificates available for hardness testing bars.
Welder Qualification Testing

B STAGE 2
(Welding Equipment Set-up & Welding Consummables)
Page 3 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Prior to welder qualifications, Shop Controls are established for welder

B1 WPS monitoring (heat input measurement & hardness tests), Sch. Q, Att. IV,
consumables, documentation & test materials.
Welder Testing (Procedures & Controls) are approved:

A) An independent 3rd party (SA approved) has been selected
SAES-W-011,
B2 B) Company is notified prior to any testing.
Section 7
C) Test Facilities are available at the Shop (to be approved).
D) Equipment meets SA standard requirements (CS, alloy & SS)
Welder Testing Facility is first approved (Safety, Electrical):

• Machine spacing & clearances (layout) is adequate and safe.
Contract Based
• Routing of cables & controls does not present safety hazards.
Safety
• Ventillation & air supply is adequate for testing/training.
B3 Requirement
• Grounding tests (equipment is well grounded) are performed
Schedule A, B,
• Electrical system & controls have been tested & are properly rated
et al
• Training/Testing areas have proper test stands and work support
• Covers (to prevent arc flash) are in place for personnel protection
Welders are considered competent, qualified through practice & trained

SAES-W-011,
B4 in WPS & SA requirements by QC in place before testing by approved
Section 7.2.5 a
3rd Party. (Identify experienced welders with JCC cards)
Welding Procedure Controls for Low Temp Applications:

• Initial welding (first ten, etc) is monitored (calibrated tong testers).
• Best welders selected (Consistently meet Heat Input & Hardness)
B5 Sch. Q, Att. IV
• Contractor use of E7018-1 (SMAW fill & cap) is strictly assured.
PMI can distinguish higher manganese content in E-7018-1
• Welders with marginal heat input results are reassigned.
Welding on NACE material is performed as follows:

A) Welders are NACE experienced & familiar with NACE WPS
B) Welders meet NACE WPS Heat Input & hardness values. NACE Standard
B6 C) NACE welders are listed on a roster & on SA JCCs. MR0175
D) CS Welders demonstrate NACE ability through daily monitoring. Section 5.3
E) Shops start early monitoring of Heat Input during training & testing to
qualify any welders for NACE welding & Low Temp applications.
Work stations for each welder are checked as follows:

A) There are a sufficient number of uncrowded work stations. ANSI Z49.1,
B7
B) Stations are level & capably support fabricated components. Annex J
C) Sufficient shielding protection exists for welder work stations.
Welder training & testing areas are segregated or in a separate area SAEP-323,
B8
where approved welders with JCCs perform shop work. Section 6
Sch. Q,
B9 Welding machines for each work station have current calibration
Section 3
Page 4 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Welding power supplies were calibrated per British Standard 7570 when SAES-W-011,
B10
impact toughness tests are required (SA, spec or code) Section 19
Welding machines (singular or banked) have sufficient spacing and ANSI Z49.1,
B11
ventilation to dissipate heat. Annex J
Welding machine leads are in good condition & are fed to each work
location as follows:
A) Organized & safely secured (tie wraps) overhead routing exist
ANSI Z49.1,
B12 B) Laid out & properly covered in walkways for access/egress
Annex J
C) Method of lay out is an orderly fashion that prevents tripping.
D) Lead routing through heavy equipment (forklift, crane, etc) area is
between 2x4's or under inverted channels to prevent damage.
Gas cylinders at welder stations are properly secured with quality hoses ANSI Z49.1,
B13
and fittings rated for use in GTAW set-ups (rigs). Annex J
Each welder is supplied with the following at his work station.

• Weld rigs (leak tested & good), Standard, Gas Lens, Mini Rig, etc...
• Gloves, Helmet, Vest
• Proper weld lenses, (shaded, clear,& cheaters)
• Portable weld rod oven (calibrated)
• Weld gages or gages are available ANSI Z87.1 &
B14 • Grinder, File, Chipping Hammer / Hammer ANSI Z49.1,
• Vise or Vises (work station) Annex J
• Level, T square, Measuring Tape
• Adequate lighting (fixed, portable, mini-lights for root pass check)
• O2 detector is available for TIG welders
• Calibrated Digital Pyrometer is available
• Supports, guides or stands as needed for pipe or structural item.
Welding Facilities (Environmental Shielding) provides adequate

protection from elements of wind, sand & rain:
A) Condition of the roof is good (no holes, missing panels, etc) SAES-W-011,
B15
B) Doors for closure are available and function properly Section 11.2
C) Partitions are installed & properly oriented for environment.
D) Wind Shields or tents are available in adequate numbers
Welding equipment set-up & testing is complete: A)

Maintenance, testing & monitoring records are available.
B) Machines have a unique ID number
C) Machines have leads and connections secured (as calibrated). D)
Sch. Q, Att. IV,
B16 Machines are properly grounded (tested & passed per results)
Section 4
E) Current Calibration sticker (checked with calibrated tong tester)
F) Machine Controls function properly & current values are legible
G) Special GTAW equipment is available (Corrosion-Resistant Mat'l) H)
Electrical supply & outlets are adequate & safely installed.
Page 5 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Welding Electrode & Consummable Storage:
A) Climate controlled storage area is clean & free of dust & moisture SAES-W-011,
B17
B) Area is secured and has counters to control access Attachment 1 & 2
C) Consummable Control personnel (issue) are available & trained
Drying, Storage & Portable ovens are operable with calibrated controls
SAES-W-011,
B18 (temperature gauge) per SAES-W-001 Table 1 Ranges. SAES-W-011,
Attachment 1 & 2
Table 1 requirements are posted near ovens.
Calibrated weld rod holding ovens are set up & controlled:

• Initial baking
• Re-conditioning SAES-W-011,
B19
• Weld rod oven interior map indicates weld rod type & location Attachment 1 & 2
• Weld rod oven interior map indicates weld rod status (final issue).
• Logs, issue slips, rod receipt records, bake records, etc, exist.
Pressurized gas cylinder (consumable) storage:

A) Designated area exists for storage of cylinders
B) Segregation (marking & identification) exists in storage area.
C) Warning signage exists for this area (No smoking, cautions, etc)
AWS Z49.1,
B20 D) Storage area is on level concrete surface with bottles upright.
Annex J
E) Storage area can be locked & secured to prevent access.
F) Locks & chains are available for cylinder storage areas.
G) Tags (certs) are attached to cylinders (from approved sources)
H) Records of receipt & documentation (log) kept on all cylinders
Shop has welding equipment (& tool) maintenance & repair ability. AWS Z49.1,
B21
Alternately, Maintenance company performs repairs. Annex J
Shop has a Tungsten grinder (diamond cutting/grinding/shaping) &
AWS C5.5,
B22 follows quality GTAW equipment & consumable handling practices.
Section 6
Procedures cover specific practice ... See Also SAIC-W-2006
Manpower Reqmts (Quantity & Qualifications) Note: Task all inspectors with reqd reading (SATIPs). Tests after required
C STAGE 2
reading are given by discipline with a goal for Process Improvement (SA System Training/Orientation)
Construction Manpower Forecast (start-up & peak) showing total Schedule Q,
C1
numbers (welders, fitters, helpers, etc) is available. Sec- VI Table 2
QC MANPOWER FORECAST (start-up & peak) showing total number of Schedule Q,
C2
inspectors, engineers & supervisors is available. Sec- VI Table 2
Schedule Q,
C3 QC Manpower meets Construction manpower ratios.
Sec- VI Table 2
CV-approved Quality personnel arrive early* (10-days before work) for Schedule Q,
C4
job training & any testing requested by Saudi Aramco. Sec- VI Table 2
Quality Personnel experience minimum requirements (Contractors or

subcontractors that perform the work) per Sch. Q:
A) Have 10 years of industrial experience minimum (Age 27)
B) Have 6 years experience in a given inspection specialty SCH. Q, Att. I,
C5 C) Have 4 years (of 6 years) in Oil & Gas (petrochemical) industry Qualification
D) High School graduate, or equivalent Requirements
E) Fully conversant with applicable Industry Standards & Specs
F) Can perform inspection functions with minimal supervision.
G) Can pass a SA interview & testing when requested by Company
Page 6 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Welding/Mechanical Inspectors:
A) Certified as a CWI, CSWIP Certified Welding Inspector.
B) Knows codes (ASME B31.3, 31.4 & 31.8, ASME V and IX, API 620 &
650, AWS D1.1, required for the execution of the WORK.
HAVE ALL
C) Can monitor NDT work & results
C6 SCH. Q, Att- I WELDING QC
D) Qualified ASNT Level II (relevant methods) when performing, viewing,
TAKE TEST
ensuring or auditing NDT specific method(s).
E) Pass interview & test given to welding QC (knows workmanship, code
undercut, WPS, socket weld specific reqmts & references, understands
service implications and RELATED SPECIFICATIONS)
Heat Treatment Inspector:

HAVE ALL
A) Five years work experience (heat treatment tech or supervisor) B)
C7 SCH. Q, Att- I PWHT QC
Knows heat treatment methods/equipment used on projects
TAKE TEST
C) Knows requirements of ASME B31.3 code & passes SA test
Coating Inspector: Inspector demonstrates a thorough working

knowledge & proven ability in critical coating applications/methods &
HAVE ALL
recognized industry standards. Inspector is qualified to NACE Level II
C8 SCH. Q, Att- I COATING QC
Critical Coatings Certification, CSWIP Level I, or equivalent.
TAKE TEST
INSPECTOR DEMONSTRATES ORGANIZATION & PROFICIENCY IN
SAES-H-100 ATTACHMENTS A, B, C, D for SA INSPECTION
NDT TECHS
All IK CONTRACTOR & subcontractor NDT personnel performing NDT
Demonstrate
operations, or interpreting, reviewing, ensuring or auditing NDT
Competency in
C9 operations meet SA requirements of SAEP-1142 & hold current NDT SCH. Q, Att- I
the field
certifications. Also, RTFI Personnel must be certified by SA.
MONITOR initial
NDT Personnel are monitored at start of work (Issue RFI).
work closely
Quality Assurance Manager is approved:

A) Has demonstrated knowledge & training (ISO-9000 int'l stds)
B) Has a university degree or equivalent
C) Has a minimum of 10 years of direct experience in QA system
Dedicated
activities in the oil, gas and petrochemical industries.
solely for QA
D) Is willing to address Quality & Continuing Process Improvements as
C10 SCH. Q, Att- I Mgr duties &
required by approved Quality Plan to SA customer satisfaction
Quality
E) Understands the entire workscope for which he is responsible
Concerns
F) Passes day-long interview & test (as needed) for new QA Mgr. Note:
Interview of Prime QA Mgr & Subcontractor QC Managers together
recommended to see how they interact as a team and respond to SA
expectations. Utilize this checklist on interview/test.
Quality Control Manager is approved:

A) Has demonstrated knowledge & training in the use of measuring and
Other Duties do
test equipment routinely used in conducting inspections.
C11 SCH. Q, Att- I not conflict with
B) Has university degree & 7 years inspection experience OR
QC Mgr duties
C) Has HS diploma with 10 years inspection experience related to
supervision of construction activities (Oil, gas & petrochemical)
Page 7 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
PMI technician & PMI procedures are available.

A) PMI technician is qualified & certified as an ASNT RT Level I
B) Has at least one year experience in using PMI instruments.
HAVE ALL PMI
C) Has passed a SA demonstration test with an approved PMI
C12 SCH. Q, Att VI, TECHS
instrument on an alloy sample with 100% correct assessment.
TESTED
D) PMI Technician works to an approved written procedure.
E) PMI technician has documented training (instrument & procedure)
Approved by COMPANY (demonstration test performance)
Crane Inspector (demonstrates thorough working knowledge of

codes such as ANSI-A17.1 & 17.2, ANSI-B30.1 through B30.16) for HAVE ALL
certification of cranes in newly constructed shops as follows: CRANE
C13 A) Concrete structural foundation inspections are performed SCH. Q, Att- I INSPECTORS
B) Calculations for foundation & anchoring are available to SA TASKED TO
C) Certs documenting Crane capacity & construction are required READ
Crane Inspectors are available for work & tasked to read
Adequate supervision is available for the quantity of shop workers for all Schedule Q,
C14
shifts. Sec- VI Table 2
Schedule Q,
C15 Adequate QC works Full Time while work is in progress.
Sec- VI Table 2
No Conflicts of Interest exist regarding personnel, NDT Companies,

Schedule A,
Third Party Inspection agency personnel & Contracted Inspection
C16 Section 20
personnel performing the work.
& Sch. Q
Personnel from other projects have approval/release letter.
D Shop Layout & Location of Facilities STAGE 2
PFI-ES-43, Environmental
D1 Shop/Yard Layout Map is available during walkdown & review.
Section 1 controls
Shop/Yard Layout is based on quality engineering controls & considers PFI-ES-43, Environmental
D2
prevailing winds, dust movement & contamination. Section 1 controls
D3 Segregated & enclosed area installations are complete.
Section 1 controls
Valve Testing Facility is upwind of CS dust & contaminants, enclosed & PFI-ES-43, Environmental
D4
shielded from the elements (fouling & contamination). Section 1 controls
D5 SS & alloy work areas are located upwind of all CS work areas.
Section 3.6 controls
D6 Coating operation is downwind or isolated, enclosed & shielded.
Section 3.6 controls
PWHT facility or area is segregated, barricaded, accessible, well SAES-W-011, Environmental
D7
ventillated, with adequate supports & weather protection for work. Section 13 controls
Radiography set-up per SAEP-1141 (Industrial Radiation Safety):

A) Shop is prepared for NDT Unit Dhahran SAEP-1141 Safety Audit
B) Copy of Radiation Safety Manual (SAEP-1141) is available SAEP-1141, Environmental
D8
C) Radiography location is isolated (2mr boundaries, barricades). Section 1 controls
D) Equipment storage areas are approved, locked and secured
E) Transportation & Handling Safety measures are known
Page 8 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Storage yard is of adequate size to accommodate the types of materials
D9 Sch. Q, Att. IV,
expected to be received during the course of the project.
Storage yard organization allows easy material access & flow (for proper
D10 Sch. Q, Att. IV,
movement & handling) during the course of the project.
Preservation & Special Storage requirements are known and adequate
space exists with carefully planned material organization.
Quarantine Areas are established (includes a tagging system) for reject
materials. Fence or other marked boundary is in place.
OFFICE SPACE clearly designated for Company & Contractor is
available. Facilities for SA work access are per the contract.
E Electrical Inspection & Safety (Access/Egress & Equipment) Identify Hazards
Contract Safety
E1 Shop has adequate lighting (fixed overhead & portable lights).
Requirement
Contract Safety
E2 Shop has sufficient electrical outlets (support for workstations).
Requirement
Contract Safety
E3 Electrical outlets & extension cords have GFI’s & dust covers.
Requirement
Contract Safety
E4 Electrical power feeds (j-boxes, power, lighting, etc) are installed.
Requirement
Terminals for weld leads & power cables are shielded from contact by ANSI Z49.1,
E5
personnel or by metal objects (vehicles, cranes, etc). Annex J
Welding Connections between welding leads & power supples are

guarded by one of the following methods:
A) Dead front construction and receptacles for plug connections ANSI Z49.1,
E6
B) Terminals located in a cover Annex J
C) Insulating sleeves
D) Other equivalent mechanical means.
ANSI Z49.1,
E7 Welding Grounds are inspected/tested & in good condition.
Annex J
The workpiece being welded & the frame or chassis of all electrically ANSI Z49.1,
E8
powered machines is connected to a good ground. Annex J
Grounding is done by locating the workpiece or machine on a grounded

ANSI Z49.1,
E9 metal floor or platen, or by connecting it to a properly grounded building
Annex J
frame or other satisfactory ground.
Chains, wire ropes, cranes, hoists, etc are not be used as grounding ANSI Z49.1,
E10
connectors or to carry welding current. Annex J
The workpiece lead is not the grounding lead. The workpiece lead ANSI Z49.1,
E11
connects the work terminal on the power source to the workpiece. Annex J
A separate lead is required to ground the workpiece or power source ANSI Z49.1,
E12
work terminal. Annex J
The welding current magnitude is safely carried by the grounding ANSI Z49.1,
E13
conductor (not overloaded, hot). Annex J
Page 9 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Areas are clear of tripping hazards. Lay out of production areas

AWS Z49.1,
E14 for gas hoses, cables, mechanical assemblies, and other equipment do
Annex J
not cross walkways or interfere with routine tasks.
Work above ground or floor level has safety rails or lines to prevent falls. AWS Z49.1,
E15
Safety lines & harnesses are available for fall protection. Annex J
Fire and explosion escape routes are identified and kept clear so that AWS Z49.1,
E16
orderly, rapid, and safe evacuation of an area can take place. Annex J
Equipment, machines, cables, hoses & other apparatus are placed to AWS Z49.1,
E17
prevent hazards to personnel in passageways. (ladders, stairs). Annex J
Warning signs are posted to designate welding areas & they specify that AWS Z49.1,
E18
eye protection must be worn. Annex J
Protective screens exist for persons in areas adjacen to welding &
cutting operations to protect them from radiant energy & hot spatter:
AWS Z49.1,
E19 A) Flame-resistant screens or shields
Annex J
B) Suitable eye and face protection and protective clothing.
C) Appropriate radiation protective semi-transparent materials
Combustible control in welding areas is handled as follows:
A) Combustibles are stored away or shielded from welding/cutting.
B) Combustible floors, roofs, partitions are not found in weld areas.
AWS Z49.1,
E20 C) Building contents including trash, wood, paper, textiles, plastics and
Annex J
chemicals are kept away from welding areas
D) Flammable gases and liquids are kept away from welding areas.
E) Outdoors, dry grass & brush are kept away from welding areas.
Excessive noise, particularly continuous noise at high levels that can AWS Z49.1,
E21
damage hearing is identified & warning signs/zones exist. Annex J
Machinery Guards are available to protect welders & other workers from
injury by machinery & equipment being operated.
A) Moving components & drive belts are covered by guards to prevent
physical contact. (especially grinders) AWS Z49.1,
E22
B) Workers are protected against accidental entry into the working Annex J
envelope of all machinery and robotic equipment.
C) Because welding helmets and dark filter lenses restrict visibility of
welders, special attention is required for these hazards.
Persons do not consume food in work areas where toxic fumes are
AWS Z49.1,
E23 generated to avoid ingestion of contaminants. Lunch areas are
Annex J
designated and wash stations are readily available.
Equipment is installed in clean, dry areas and adequately protected from AWS Z49.1,
E24
dirt and moisture. Annex J
EQUIPMENT for use is adequate for the scope of work required.

A) Structural support fabrication areas & equipment are adequate
AWS Z49.1,
E25 B) Structural steel (jigs and cutting machines) are in good condition.
Annex J
C) Pipe rolling method exists for thick segments
D) Air Compressors are adequate for supply at peak of work.
Contract Safety
E26 Shop floors are level, clean and stable for ongoing work.
Requirement
Page 10 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Contract Safety
E27 Shop has adequate ventilation and air movers.
Requirement
Contract Safety
E28 Fire Extinguishers are stationed throughout the work areas
Requirement
Overhead cranes (existing shops) for lifting have current certification, are Contract Safety
E29
properly rated, & are found in good condition. Requirement
CRANE CERTIFICATION for smaller cranes in newly constructed shops

must be documented as follows prior to shop approval:
Contract Safety
E30 A) Concrete structural foundation inspections are performed
Requirement
B) Calculations for foundation & anchoring are available to SA
C) Certs documenting Crane capacity & construction are required
Contract Safety
E31 Portable hoist & fork-lifts are rated & in good working condition.
Requirement
Contract Safety
E32 Access & egress pathways for fork-lifts & hoists are sufficient.
Requirement
Contract Safety
E33 Sufficient passage ways exist for personnel exit in an emergency
Requirement
Contract Safety
E34 Lifting components (slings, shackles, wire ropes, etc) are good.
Requirement
Contract Safety
E35 Overhead crane installations have been inspected & load tested.
Requirement
Contract Safety
E36 Storage racks & shelves are level & sufficiently supported
Requirement
Safety Lanes (for access/egress) are marked in saftey colors such as Contract Safety
E37
yellow & black, etc to identify hazards Requirement
Contract Safety
E38 Safety Signage & Markings identify hazards (posts, doorways, etc)
Requirement
Disposal bins (trash cans, metal refuse, plastics, etc) are marked to Contract Safety
E39
identify contents allowed inside them (fire hazard warnings). Requirement
Contract Safety
E40 Overall housekeeping of the shop is sufficient to prevent a fire.
Requirement
Paints, coatings & NDT supplies are stored per manufacturer's Contract Based
E41
recommendations in climate controlled areas out of direct sun. Requirement
Cleaning materials & chemical storage as follows:
A) Flammable material storage is away from heat/electrical sources
• Storage is per manufacturer's (warning label) data sheet (MSDS) Contract Based
E42
B) Cloths & Rags are stored & issued by Consummable Control Requirement
• Cloth & rag storage bins have covers that are kept closed.
• Used (refuse) Cloth & rag disposal bins are available.
Contract Safety
E43 Supervisors & workers know protocol in case of emergency
Requirement
Contract Safety
E44 Emergency services (ambulance) is available.
Requirement
Precautionary labels on consumables & equipment concerning the safe Contract Safety
E45
use of the products are available for reading & guidance. Requirement
Approve SS
F Austenitic Stainless Steel & Nickel Alloy Shops PID Guide
Shop
Page 11 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Stainless Steel & Nickel Alloy Shops address material Handling &
PFI-ES-43,
F1 Storage, Fabrication & Shipping per Piping Fabrication Institute (PFI)
Section 1
Standard ES-43.
Stainless Steel & Nickel Alloy Shops are safely & properly ventillated PFI-ES-43,
F2
(ANSI Z49.1). Adequate air movers lift toxic fumes. Section 1
Handle Austenitic stainless steel & nickel alloys with nylon slings or PFI-ES-43,
F3
equipment protected with a non-contaminating buffer mat'l. Section 2.1
Receive these alloys and conduct a visual exam of both internal &
PFI-ES-43,
F4 external surfaces to detect existing contamination or gouges caused by
Section 2.2
contact with contaminating material.
Fittings are stored on pallets or shelving that is constructed of non- PFI-ES-43,
F5
contaminating material. Section 2.3
Storage areas for these materials are separate from the areas where PFI-ES-43,
F6
carbon steel material is stored. Section 2.4
PFI-ES-43,
F7 SS material stored outdoors is covered with water repellent sheet.
Section 2.5
Carbon steel strapping is used if a durable, non-contaminating material
(clean wood, cardboard, cloth, paper & SS buffer) isolates the strapping PFI-ES-43,
F8
from contact with the stainless steel or nickel alloy. Section 2.6
Gray duct tape (high chlorides) is absolutely prohibited
PFI-ES-43,
F9 Walking on austenitic SS or nickel alloy material is not allowed.
Section 2.7
Fabrication requirements (austenitic stainless steel or nickel alloy): A)
PFI-ES-43,
F10 Contact surfaces of tools & equipment containing CS, zinc, copper or
Section 3.1
their alloys are covered in a noncontaminating material.
Tools such as grinding wheels & wire brushes previously used on carbon PFI-ES-43,
F11
steel are not used on stainless steel or nickel alloys. Section 3.2
Grinding discs, abrasive discs & belts are made of resin-bonded PFI-ES-43,
F12
alumina, silicon carbide or zirconium carbide. (No Sulphurized items) Section 3.3
PFI-ES-43,
F13 Only 300 series SS brushes are used on austenitic & nickel alloys.
Section 3.4
All material removal & cleaning tools are marked to identify that they are
PFI-ES-43,
F14 to be used on austenitic & nickel alloy materials only.
Section 3.5
Marking is visible while a tool is in use. (Purple color code)
Austenitic & nickel alloy material fabrication areas are separated from PFI-ES-43,
F15
CS areas (upwind to prevent cross contamination). Section 3.6
Suitable methods prevent cross contamination by CS shavings, grinding

dust, & zinc dust from coating operations as follows: PFI-ES-43,
F16
A) Enclosure, separation & location of work areas is adequate Section 3.6
B) Engineering controls & ventillation assure cleanliness & safety
Where tape is used for back purging, the tape uses an adhesive with a PFI-ES-43,
F17
water soluble chloride content not exceeding 50 ppm. Section 3.7
Pressure-sensitive & adhesive-backed tapes removed (along with any PFI-ES-43,
F18
residual adhesive) utilize a suitable solvent or abrasive. Section 3.8
Page 12 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Cutting fluids or oils are low halogen, low sulphur & are completely PFI-ES-43,
F19
removed from all surfaces prior to any welding or forming. Section 3.9
Shipping of materials utilizes new packing materials & shipping

PFI-ES-43,
F20 protectors such as PVC caps, plugs, & new adhesive tapes. No harmful
Section 4.1
substances are utilized in shipping.
Certified chloride-free marking or color coding has a water soluble PFI-ES-43,

F21
chloride content below 50 ppm (measured after drying). Section 4.2
Identification tags & Attachment devices used are made of PFI-ES-43,

F22
noncontaminating materials. Section 4.3
Austenitic stainless steel & nickel alloys are shipped in a manner that will PFI-ES-43,
F23
minimize the risk of the material becoming contaminated. Section 4.4
Shipping alloys on same load as CS material ensures segregation PFI-ES-43,

F24
through use of wood bracing or other non-contaminating material. Section 4.4
Equipment for Corrosion-resistant Material Welding such as austenitic

stainless steel (excluding types 304/304L/316/316L), or nickel-based
alloys meets these specific requirements:
A) All manual GTAW uses a high frequency start & post-purge gas flow
for the torch. SAES-W-016,
F25
B) A remote contractor & current control (pedal or torch mounted). Section 6
C) Pre-set power source current start/rise and decay/stop controls
triggered by a foot switch or torch mounted control is an acceptable
alternative for the remote control.
D) O2 Analyzers & proprietary dissolvable (water soluble) dams
G NACE & NACE Low-Temp Material Shops
NACE MR0175,
G1 NACE Material Fabrication shops are segregated from other CS.
Section 1
NACE Material Fabrication for NACE varieties are segregated from each NACE MR0175,
G2
other (NACE CS, NACE Low Temp CS, NACE alloy & SS). Section 1
NACE Material ID is by low stress stamp & unique color-code. Segments NACE MR0175,
G3
are stamped before cutting. Section 1
NACE Material storage is segregated by color code. (NACE CS, NACE NACE MR0175,
G4
Low Temp CS, etc). NACE varieties are not mixed together. Section 1
Careful Handling of NACE materials does not create susceptibility to

Stress Corrosion Cracking in finished welds as follows: NACE MR0175,
G5
A) Heavy hammering is never allowed on NACE materials. Section 1
B) Identification stamps use low-stress stamps.
H Field & Yard Welding (Outside of a Shop)
Page 13 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
SA Inspection approves indoor facilities (shops). Welding outdoors at a

Shop facility in a yard is considered Field welding, & subject to increased
NDE extent per SAES-W-011 as applicable: A) Develop &
Low Temp (-18C MDT) applications outdoors receive 100% NDE Utilize Spec-
SAES-W-011,
H1 B) Alloy steel (P-No. 4 & above), stainless, & nonferrous materials (all Check ASAP
Section 17.5
services except Cat. D fluids) welded outdoors are 100% NDE. on Projects
C) Severe Cycle (Cat. M) shall be identified (100% NDE, 0 undercut) Attachment 2
Follow SAES-W-011 Guideline carefully based on NDT Specs
Create SPEC-CHECK as a field surveillance & review tool
Work stations located outside of a Shop in a Yard:

A) The areas for work are properly identified as work stations.
B) Stations are level & capably support fabricated components. SAES-W-011,
H2
C) Sufficient shielding & weather protection exists for stations. Section 17.5
D) Adequate power & remote welding controls exist for stations.
Additional NDE is required for Yard Welding Operations.
Remote Current Control use (field welding) is available for welding more SAES-W-011,
H3
than 30 meters from power source (remote locations) Section 19
Quality Plan &
I Procedures, Documentation & Records Control of Work
Sch Q reqmt
Approved procedures (required by Sch. Q) are available and understood Provide
I1 QP
by the workers and QC. Instructions
Provide
I2 Approved WPS are posted in multiple conspicuous work areas. QP
Instructions
Provide
I3 Current AFC/ IFC drawings are issued & available for work QP
Instructions
Document
I4 Controlled record storage, i.e. offices, file cabinets, etc, is adequate QP
Quality
Document
I5 Computer availability for record storage and back-up is adequate. QP
Quality
Contractor has a filing system for the following:

• Calibration records
• Material receipt records, CMTRs, Mill certs, valve reports, etc
Document
I6 • Consumables & records QP
Quality
• Welder certs
• Drawing register
• Construction forms & records (spools, materials, coating, etc)
Database per SAEP-1160 & SAIC-W-2008 for tracking and status

• Weld ID system (Full Pen Butt welds, socket/groove & fillet)
• Track weld special process until completion (PWHT, HT, PMI, etc) Document
I7 SAEP-1160
• Track welder performance Quality
• Track modifications (repairs) after completion
• Track Pressure Tests (SAIC-A-2001 & Procedure detail steps)
See Other
J Valve Testing Shop
Checklist
Page 14 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Valve Testing at new shops is approved by SA Proponent as a desirable SAES-L-108,

J1
location for any field testing prior to line installation. Section 4 4.7.1
SAES-L-108,
J2 Proper segregation exists for CS, NACE & SS valve materials.
Section 4
An adequate water supply (treated or demin water) exists & meets SA SAES-L-108,
J3
SAES-A-007 requirements for testing and purity. Section 4
Test Equipment is available as follows and does not promote fouling &
contamination of alloy components:
SAES-L-108,
J4 A) Pressure Test manifold rated for work per SAES-A-004 reqmts.
Section 4
B) Pressure hoses rated for the work
C) Water tanks, mixing apparatus & filling hoses
SAES-L-108,
J5 Procedure for Field Testing of Valves is approved.
Section 4
Personnel including QC dedicated to Valve receiving inspection & field SAES-L-108,

J6
testing have experience with valves and have been approved. Section 4
List of valves to be tested is available before the start of work & meets SAES-L-108,
J7
SA standards and approved testing procedure. Section 4
Records, QC form & unique ID numbers will exist for every valve tested. SAES-L-108,
J8
Valves are traceable to their unique test reports. Section 4
See other
K Coating Facility
checklist
Coating Works QC Set-up meets SAES-H-100 as follows:

A) QC Equipment Kit (SAES-H-100 Attachment A Checklist Items)
SAES-H-100,
K1 B) QC Equipment Check Sheet (SAES-H-100, Att B) available
Section 9
C) In-Process Inspection Sheet (SAES-H-100, Att C) available
D) Paints/Coatings & Equipment Log (SAES-H-100, Att. D) available
Ground is blacktop or marl base that will not allow dust from grade to rise SAES-H-100,
K2
& stick to wet paint. Section 9
Protection from the elements (sun, wind blown sand & dust, moisture) is SAES-H-100,
K3
adequate for coating applications. Section 8
Overspray protection (within the facility) is adequate & does not affect PFI-ES-43,
K4
other ongoing fabrication work. Section 3.6
Coating material storage areas meets SA & manufacturer data sheet SAES-H-100,
K5
environmental condition requirements. Section 6
SA Inspection approved initial set-up, Qualification report & the field SAEP-316,
K6
demonstration & issued JCC cards to applicators. Attachment A, B
Coating Inspector qualification report & Inspector clearance card has SAEP-316,
K7
been issued after successful inspection during demonstration. Attachment C, D
See other
L Material Handling and Storage
checklist
Page 15 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Pipe handling procedure including equipment used for handling is

Company approved and good practice is in effect as follows:
A) Material is not rolled/dropped off trucks during unloading.
B) Material is stacked properly to protect pipe and coatings. SAES-L-450
L1
C) Slings are nylon or similar and wire rope slings are not used. Section 8
D) Metal hooks are padded to prevent contact damage to coating
E) Internally coated fittings are handled on the OD only.
F) Bevel protectors remain intact and don't damage coatings.
Components are protected from mechanical damage with welding ends

protected with suitable wood, plastic, or metal covers and all fittings
packaged in steel-banded wooden crates or secured to skids in staging 02-SAMSS-005
L2
areas for field use as follows: Section 10
A) All fittings (02-SAMSS-005, Section 10)
B) All flanges (02-SAMSS-011, Section 10)
Field facilities for storage/preservation of materials are approved prior to

the start of piping installation as outlined in SAES-L-350 Section 7 and
as follows:
A) On-Plot Material Warehouse and Storage Facilities Sch Q
L3
B) Field Welding Consumable Storage Facilities Attachment IV,
C) Yard Welding Areas/Shops (CS, alloy and SS areas)
D) Spool Storage areas, Lay Down Yards and staging areas
E) Site Valve Testing Facility, Site Instrumentation/Testing facility
The minimum amount of temporary support is available and spools are

not laying on the ground. They are supported on wooden cribbing in SAES-L-350
L4
approved staging areas. Fittings and valves are covered and stored in Section 7
shipping crates or on racks off the ground.
Stainless steel spools, components and other materials are kept covered SAES-L-350
L5
during storage in lay down yards and staging areas. Section 7
System for Plate, Piping & Material Receipt Inspection, Material Matl Id & Item in QP or
M
Management & Storage Traceability Procedure
A "System" used for documentation regarding ID & Traceability for Item in QP or

M1 Sch Q, Att - IV
spools & structural assemblies (traceability to CMTRs) exists. Procedure
CS Shop Storage areas (inside the shop) are adequate in size for large Item in QP or
M2 Sch Q, Att - IV
& small materials, well marked, organized & segregated. Procedure
Item in QP or
M3 Storage bins for cut items are marked & organized. Sch Q, Att - IV
Procedure
Item in QP or
M4 Shop has segregated areas for reject & unusable scrap materials. Sch Q, Att - IV
Procedure
Storage areas (inside the shop) are off the ground & adequate wood Item in QP or
M5 Sch Q, Att - IV
(dunnage) or other supporting materials exist. Procedure
Quarantine "Tagging System" used to segregate & store reject material Item in QP or
M6 Sch Q, Att - IV
does not invite use of unauthorized/rejected items. Procedure
Quarantine "System" Disposal Rules are in effect & disposal schedules Item in QP or
M7 Sch Q, Att - IV
are available (Sch. G rules apply here also). Procedure
Matl Id & Item in QP or
N System for documentation (Spool ID & Traceability)
Traceability Procedure
Page 16 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
COMPLETE TRACEABILITY is easily demonstrated for all components Item in QP or

N1 Sch Q, Att - IV
of pipe spools & structural assemblies Procedure
Item in QP or
N2 Traceability to CMTRs (system) is documented & well organized. Sch Q, Att - IV
Procedure
Item in QP or
N3 Drawings & Revision Control system in place are organized. Sch Q, Att - IV
Procedure
Item in QP or
N4 Report Records (sytem) is available for spool ID & traceability Sch Q, Att - IV
Procedure
Item in QP or
N5 QC forms exist for spool ID & traceability. Sch Q, Att - IV
Procedure
Data Report Contents provide adequate tracking & information. SAIC-W- Item in QP or
N6 SAEP-1160
2008 (DATABASE) & SAIC-A-2001 (PRESSURE TESTS) Procedure
O System for Identification Transfer after cutting
Item in QP or
O1 System (procedure) for transfer of ID BEFORE cutting exists Sch Q, Att - IV
Procedure
Item in QP or
O2 System for transfer contains Unique Identification Numbers or UINs Sch Q, Att - IV
Procedure
System can be followed by those who do not speak or write in English.
Example: Manoj is cutting two small diameter pipe lengths (different
Item in QP or
O3 grade CS). Small pieces can easily be mixed, misplaced, dropped or Sch Q, Att - IV
Procedure
placed in bins with other materials. Safeguards in place prevent this
occurrence. Identification methods are effective.
Material markings for identification are permanent marks that remain Item in QP or
O4 Sch Q, Att - IV
intact & legible on the material until recorded into QC records. Procedure
Color code remains intact after cutting of pieces. System to disposition Item in QP or
O5 Sch Q, Att - IV
missing & faded color coded segments exists. Procedure
P Color Coding Verification Upon Receipt
Disposition rules for missing & faded (unidentifiable or questionable Items in QP or
P1 Sch Q, Att - IV
grade) color coded piping & materials exist. Procedure
Items in QP or
P2 Quality Control (verification) is always performed upon receipt. Sch Q, Att - IV
Procedure
Only Quality Personnel may approve repainting after the following:
• Materials have been verified (CMTR & UIN) for distinct color code.
Items in QP or
P3 • Quality Control documentation & issuance of NCR against Vendor Sch Q, Att - IV
Procedure
• Notification & approval from Saudi Aramco is received
• Positive Material Identification verifies composition (alloy, SS items)
Material Receiving Inspection personnel (quality) are adequately trained
Items in QP or
P4 and can identify missing, faded and improper (mixed) color coded items Sch Q, Att - IV
Procedure
that arrive on site.
Repainting is done with correct RAL paint per applicable SAMSS Items in QP or
P5 Sch Q, Att - IV
requirement (length & size of striping). Procedure
Items in QP or
P6 Positive Material Identification (PMI) is witnessed. Sch Q, Att - IV
Procedure
Page 17 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
System Identification (Pipe Spools, Pipe Lengths, etc) Matl Id & Item in QP or
Q
After Sandblasting & Coating Traceability Procedure
Items in QP or
Q1 System for Identification after sandblasting/coating exists Sch Q, Att - IV
Procedure
System prevents sandblasting removal of UINs (Unique Identification
Numbers) & resulting loss of traceability
Items in QP or
Q2 • Protective tape covering stamp identifcation adjacent to weld Sch Q, Att - IV
Procedure
• Marking inside spools with permanent marker (systematic marking)
• Application of wire & stamped tags showing spool or segment UIN
System protects UINs after coating
• Remarking restrictions (QC notified) are identified Items in QP or
Q3 Sch Q, Att - IV
• Stamped tag identification method is employed Procedure
• Verification of UIN is performed by QC
R System Controls for Special Process (NDE, PMI, PWHT, etc)
System of checks & control is in place for materials requiring special Items in QP or
R1 Sch Q, Att - IV
processes (NDE, PMI, PWHT, BHT, etc). Spool Clearance!!! Procedure
Items in QP or
R2 Personnel are trained & understand this system of control Sch Q, Att - IV
Procedure
Identification status through special flagging & marking systems can
physically identify spools & materials:
Items in QP or
R3 A) Requiring a special process Sch Q, Att - IV
Procedure
B) Completed and accepted special process
C) Completed and rejected special process
System Documentation & Tracking Records are in place to identify all
Schedule Q &
material special processes required before fabrication:
SAEP-1160 Items in QP or
R4 A) Spool tracking & clearance Sheets
Database Procedure
B) NDE Clearance (RT Trackers, RT Backlog Control, etc)
Reqmts
C) Coatings Application Tracking
Isolation rules & methods are employed for special processes:

A) Segregation employed is effective
B) Signs & barricade warning tape exist (segregated areas) Items in QP or
R5 Sch Q, Att - IV
• RT pending Laydown & Staging Areas Procedure
• PWHT pending Laydown & Staging Areas
• Coating Pending Laydown & Staging Areas
Hold status (tagging, etc) system exists & is understood to prevent Items in QP or
R6 Sch Q, Att - IV
shipments of materials & spools not accepted by Quality. Procedure
Items in QP or
R7 Completed Spool Staging Area(s) (Ready to ship, etc) exist. Sch Q, Att - IV
Procedure
S System Controls for In-Process Spools
Piping spools (assemblies) are checked, cross referenced & clearly

Schedule Q &
marked after in-process verification of dimensional requirements.
SAEP-1160 Items in QP or
S1 • Fit-up OK, Inspector initial & date, etc
Database Procedure
• Visual weld (VT) OK, Inspector initial & date
Reqmts
• Final Dimensional check (Final) OK, Inspector initial & date
Page 18 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
T In-progress Radiographic Testing & Reporting Controls
RT selection process has the highest integrity possible

• Subcontractor QC does not exclusively select welds to be RT'd. Guide for
• Contractors maintain tight control over selection of Random RT. approval of NDT
T1 Sch Q, Att - IV
• Subcontractor & Contractor QC work together in selection & invite control
Company QA personnel into the process in a spirit of Teamwork. Procedures
RT Selection Process is closely watched & monitored
RT shooting lists are available & system is monitored as follows:
• Daily RT Shoot List is always available to Contractor & Company Guide for
• RT Shoot List Results (previous day) are checked every day. approval of NDT
T2 Sch Q, Att - IV
• Tracking of Reject welds & reshoots are carefully monitored control
• Penalty shot selection is carefully monitored Procedures
• Defect location marking is carefully performed & monitored
Daily RT shooting lists with Reshoots (film & weld quality) identify shots
Guide for
as follows: • The cause of
approval of NDT
T3 the Reshoot is identified (in writing) on the Shoot list. Sch Q, Att - IV
control
• Penalty shots are identified on the list.
Procedures
• Repair attempts (R1or R2) are identified on the Shoot list.
RT Clearance (Repaired welds, reshoots, penalty shots) are closely
Guide for
monitored by Contractor
approval of NDT
T4 • Poor welder performance is identified very early in the process. Sch Q, Att - IV
control
• Poor RT technique & performance is identifed & corrected early.
Procedures
• RT Clearance is verified by SA Level III at the earliest opportunity.
RT Backlog is closely monitored by Contractor & Subcontractor. Guide for

• Backlog goals are set & maintained early in the project. approval of NDT
T5 Sch Q, Att - IV
• System of tracking reports RT Backlog numbers regularly (weekly) control
• Backlogs exceeding 100 joints receive immediate attention to clear Procedures
U System Controls
Tracking System for organization of material & storage is in place

U1 Sch Q, Att - IV
(Demonstrate how a piece of pipe and fittings become a spool)
U2 Signs in Segregated Areas exist (materials, warnings, etc) Sch Q, Att - IV
U3 Segregation Area rules exist and are followed. Sch Q, Att - IV
Material Receiving Personnel are of adequate number & are properly

U4 Sch Q, Att - IV
trained and available.
QC Inspection Personnel are adequate in number per Sch. Q & are

U5 Sch Q, Att - IV
properly trained & approved by Company prior to start of work.
U6 Tracking system for spools is available (QC tracking lists, etc) Sch Q, Att - IV
U7 Color Coding system is approved (PFI-ES-22 & SAES-A-206) Sch Q, Att - IV
Page 19 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
U8 Material Storage Yard is level and properly compacted or asphalted Sch Q, Att - IV
Pipe racks or supports (metal, wood) are adequate to provide full support
U9 Sch Q, Att - IV
to new piping (3 to 4 sets) with no bowing or sagging
Material Receiving Yard is of adequate size for significant quantities of

U10 Sch Q, Att - IV
piping to be received
U11 Safety Signs (access/egress/overhead crane/etc) exist Sch Q, Att - IV
U12 Overhead crane construction is complete and approved by SA. Sch Q, Att - IV
U13 Overhead crane certification is available to SA Safety & Insp. Sch Q, Att - IV
V System Controls for Handling Materials
The System used for handling all types of materials meets minimum
V1 Sch Q, Att - IV
industry requirements and good practice
Equipment is properly outfitted to handle a variety of materials:

V2 • Stainless & alloy materials are not directly handled with CS Sch Q, Att - IV
• Coated materials & spools employ equipment protection coverings
W Material Warehouse & Controlled Climate Storage
Manufacturer
W1 5 M + E (Coating Consumables, Welding Electrodes, etc) Sch Q, Att - IV
recommended
X Equipment Check Points
Proper cleaning equipment (tools) for all diameter piping fabrication is

available at the shop in adequate numbers as follows:
A) Variety of grinders (internal, external prep of metal surfaces) PFI-ES-5,
X1
B) Attachments (grinding wheels, cones, stones, flappers, etc) Section (All)
C) Slag hammers, chipping tools, brushes (Each worker)
D) Adequate rags, cleaning solvents (Storage Room Control)
PFI-ES-05,
X2 Demineralized water (treated water) supply exists for SS shops
Section 4
Drills (various size) & presses are adequate in their number & condition PFI-ES-21,
X3
for small diameter pipe openings. (No torches allowed) Section (All)
Internal machining tools (beveling, preparation) provide a quality surface PFI-ES-21,

X4
finsih & allow fit-up of GTAW process butt welds Section (All)
PFI-ES-24,
X5 Bending equipment is available & in good condition.
Section (All)
Page 20 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
Procedure for pipe bending methods is approved (by CSD).

A) Hot bending methods (Furnace, Incremental, & Induction bending)
PFI-ES-24,
X6 B) Cold bending methods (Rotary draw, ram & roll bending)
Section (All)
C) Bends are examined, protrusions repaired (VT, MT/PT, UT) &
gauging internals is performed (deformation, 97.5% nominal id)
Pipe ovality repair tools (jacks, crescents*) for repairs to 3% out. PFI-ES-24,
X7
* SMYS values are not exceeded. A 30-ton jack for CS (maximum) Section (All)
X8 Pipe ovality repair procedure is approved & details equipment. Sch Q, Att - IV
X9 Demineralized/Treated water supply (tank) exists for SS shop. QP scope of work
Flapper wheels to obtain ID cleanliness needed. Solvents for degreasing

PFI-ES-5,
X10 and cleaning piping after cutting operations needed.
Section (All)
See PFI ES-5
Bevel machines are in good condition. Means to meet groove weld

X11 QP scope of work
parameters is acceptable to Company & gauges are available
Y Measuring & Test Equipment (M&TE) for Welding
Adequate quantities of the following M&TE exist:

A) Hygrometers
B) Digital pyrometers
C) O2 Analyzers Items in QP or
Y1 QP
D) Calibrated tong testers Procedure
E) Weld gauges (fillet, VWAC, Hi-Lo, etc)
F) Calipers, tapes & levels
Record log (certs, calibrations, etc) exists for all M&TE
AUDITS for main shops for Carbon steel should be performed with
attention to the elements listed in Piping Fabrication Institute ES-05, 21,
Items in QP or
Y2 22, 24, 26, 27, 31, 37 and 41. Company will give close attention to QP
Procedure
systematic material and consumable control. Conduct shop audit well
before offering the shop for Company approval.
REMARKS: PASS ALONG THIS CHECKLIST AT TIME OF INTERVIEW OF SUBCONTRACTOR

& PRIME CONTRACTOR QA/QC MGR INTERVIEW TO TASK THEM TO ASSURE A SMOOTH
QUALITY START ON PROJECTS
REFERENCE DOCUMENTS:
Contract Schedule Q (Date Variable) Quality Assurance and Control, Inspection and Testing
01-SAMSS-010 - Fabricated Carbon Steel Piping (25 May 2011)
02-SAMSS-005 - Butt Welding Pipe Fittings (20-Feb. 2012)
012-SAMSS-008 - Erection of Structural and Miscellaneous Steel (9-May 2011)
SAEP-1141 - Industrial Radiation Safety (8-Dec-2010)
SAEP-323 - Performance Qualification Testing of Contract Welders and Brazers (01 July, 2008)
SAES-A-206 - Positive Material Identification (30-April 2011)
Page 21 of 22
SAIC- L-2031 30-Apr-13
ITEM
No.
SAES-H-200 - Storage, Handling and Installation of Externally Coated Pipe (24 Oct 2011)
SAES-L-310 - Design of Plant Piping (29 April, 2007)
SAES-L-350 - Construction of Plant Piping (22 April 2009)
SAES-W-011 - Welding Requirements for On-Plot Piping (4-Oct. 2009)
ANSI/AWS Z49.1 - Safety in Welding, Cutting & Allied Processes (January 2004 Edition)
ANSI/AWS D1.1-96 - Structural Steel Welding Code (2004 Edition)
ASME B31.3 - Process Piping (2010 Edition)
NACE Standard MR0175 - Sulfide Stress Cracking Resistant Metallic Materials (2002 Edition)
NACE Standard RP0472 - Methods & Controls (Prevent In-Service Cracking of CS Welds in Corrosive Environments (2000)
PFI (Piping Fabrication Institute) Standard ES-01 - Internal Machining for Circumferential Butt Welds (2001 Edition)
PFI Standard ES-02 - Method of Dimensioning Piping Assemblies (2000 Edition)
PFI Standard ES-03 - Fabrication Tolerances (2000 Edition)
PFI Standard ES-05 - Cleaning of Fabricated Piping (1999 Edition)
PFI Standard ES-11 - Permanent Marking of Piping Materials (1998 Edition)
PFI Standard ES-21 - Internal Machining & Fit-up of GTAW Root Pass Circumferential Butt Welds (2001 Edition)
PFI Standard ES-22 - Color Coding of Piping Materials (1999 Edition)
PFI Standard ES-24 - Pipe Bending Methods, Tolerances, Process & Material Requirements (2001 Edition)
PFI Standard ES-26 - Welded Load Bearing Attachments to Pressure Retaining Piping Materials (1999 Edition)
PFI Standard ES-27 - "Visual Examination" The Purpose, Meaning & Limitation of the Term (2000 Edition)
PFI Standard ES-31 - Standard for Protection of Ends of Fabricated Piping Assemblies (2000 Edition)
PFI Standard ES-32 - Tool Calibration (2000 Edition)
PFI Standard ES-37 - Standard for Loading & Shipping of Piping Assemblies (2000 Edition)
PFI Standard ES-41 - Standard for Material Control & Traceability of Piping Components (1998 Edition)
PFI Standard ES-43 - Standard for Protection of Austenitic Stainless Steel & Nickel Alloy Materials (1999 Edition)
Contractor Saudi Aramco

Construction Rep. PMT Representative:
Name, Initials, & Date: Verified  Reviewed 
QC Inspector PID Representative:
Name, Initials & Date: Verified  Reviewed 
QA/QC Supervisor Proponent and Others:
Name, Signature & Date: Verified  Reviewed 
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED
Page 22 of 22

SAUDICO Pipe Fabrication Shop Approval Checklist

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SAUDICO Pipe Fabrication Shop Approval Checklist

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2012) Rev 6 31-Mar-12

SAIC NUMBER DATE APPROVED DISCIPLINE

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

1. Contractor informs Company when a Subcontractor (or his own)

A Special Process Procedures & Controls (For Shop Start-up) STAGE 1

Special Process Procedures were submitted 30 days prior to the start of

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

Welding Procedure Qualifications (for new shops):

WPS Drawing Details (CSD common revisions):

WPS Miscellaneous details (CSD common revisions):

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

NDT/NDE Technique procedures have been Dhahran approved

NDT/NDE CONTROL procedures are issued and clear for all

PMI procedures & Equipment (Package) is CSD approved

Heat Treatment Procedure & Equipment Package is CSD approved

Heat Treatment (associated process) requirements:

Welder Qualification Testing

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

Prior to welder qualifications, Shop Controls are established for welder

Welder Testing (Procedures & Controls) are approved:

Welder Testing Facility is first approved (Safety, Electrical):

Welders are considered competent, qualified through practice & trained

Welding Procedure Controls for Low Temp Applications:

Welding on NACE material is performed as follows:

Work stations for each welder are checked as follows:

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

Each welder is supplied with the following at his work station.

Welding Facilities (Environmental Shielding) provides adequate

Welding equipment set-up & testing is complete: A)

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

Calibrated weld rod holding ovens are set up & controlled:

Pressurized gas cylinder (consumable) storage:

Quality Personnel experience minimum requirements (Contractors or

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

Heat Treatment Inspector:

Coating Inspector: Inspector demonstrates a thorough working

Quality Assurance Manager is approved:

Quality Control Manager is approved:

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY

K. Raja Roa RFI No. REQUESTED INSPECTION DATE

PMI technician & PMI procedures are available.

Crane Inspector (demonstrates thorough working knowledge of

No Conflicts of Interest exist regarding personnel, NDT Companies,

D Shop Layout & Location of Facilities STAGE 2

Radiography set-up per SAEP-1141 (Industrial Radiation Safety):

EQUIPMENT ID NUMBER EQUIPMENT DESCRIPTION EQPT CODE SYSTEM

LAYOUT DRAWING NUMBER REV. NO. S/U SYSTEM FACILITY