C.A.T.

GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

CONTRACT NUMBER 6600032833

BI-10-01282
MASTER GAS SYSTEM (MGS)
56"EGW-2 LOOP-1
FOR

SAUDI ARAMCO
Inspection and Testing for Above Ground Piping Works
(QA/P144I.Doc)

0
Rev

QC Manager
Prepared By

QC Manager
Controlled By

20.04.2014
Date

Project Manager
Approved By

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

Table of Contents

1.

PROCEDURE NO.

2.

SCOPE AND PURPOSE

3.

APPLICABILITY

4.

RESPONSIBILITY

5.

GENERAL

6.

DEFINITIONS

7.

PROCEDURE
7.1.
7.2.
7.3.
7.4.
7.5.

Receiving Inspection
Field Shop Fabrication Inspection
Post Weld Inspection of Spool
Painting of Spools
In Process Inspection and Testing For Field Fabrication and Erection Of
Above Ground Pipe
7.6. Radiographic Inspection
7.7. Pressure Testing of Spools:
7.8. Pipe Supports
7.9. Piping Completion and Inspection (Punch Out)
7.10. Pressure Testing
7.11. Testing

8.

RECORDS

9.

REFERENCES

10.

ATTACHMENTS

C.A.T. GROUP QUALITY ASSURANCE

1.

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

PROCEDURE NO.
P144I

2.

SCOPE AND PURPOSE

This procedure covers the Inspection and Testing for the fabrication and installation
of Above Ground Piping Works in accordance with Client requirements and
specifications.
The purpose of this procedure is to define a documented and recorded
methodology for the Inspection and Testing activities and to ensure that Above
Ground Piping Works construction is executed in accordance with Client
Requirements, drawings and specifications.

3.

APPLICABILITY
All Above Ground Piping Installations.

4.

RESPONSIBILITY

5.

Project Manager
Discipline Engineer
Discipline Foreman
QA/QC Supervisor
QC Inspector
Planning Engineer
Material Controller

GENERAL
5.1.

The responsibility for the Inspection and Testing of the Above Ground Piping
Works rests primarily with the QC Inspectors, Material Controller, the
Discipline Engineer and the Discipline Foreman with assistance from and
audit by the QA & QC Managers.

5.2.

The Discipline Engineer and the Discipline Foreman shall ensure the
required work permits are available and in place on a daily basis. Similarly
they shall ensure that utilized drawings are latest revision

5.3.

The Project QA & QC Managers shall perform reviews on all Quality related
contractual documentation

5.4.

The QC Inspector shall be responsible for witnessing tests and inspections

and ensure appropriate documentation in accordance with relevant SATIP.

5.5.

QC Managers shall ensure that all welding procedures (WPS), PQR and
WPQ are approved and welders are issued with J.C.C.s as per SATIP-W011-01 before start of piping fabrication,
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C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

5.6.

Welding Procedures should be displayed in fabrication workshop and other

locations where welding is being carried out.

5.7.

Only piping material required for shop fabrication should be issued during
fabrication stage. Site installation material like valves, gaskets, bolts and
equipment etc. should be released from stores only at installation stage.

5.8.

Welding consumables as per WPS requirements should be available in

warehouse. Baking, storage and handling of welding consumables shall be
as described in storage and handling of electrodes Procedure P166, SATIPW-011-01 and SAES-W-011.

5.9.

NDE Equipment and Crew should be available at site parallel to shop

fabrication work and NDE procedures and crew should be duly approved as
required by SAEP 1142 and SATIP-NDE-RT-01.

5.10. Painting/coating yard, painting/coating procedures, and approved material

should be ready before starting of fabrication works.
5.11. Hydrostatic test procedure, test media, and equipment should be ready for
testing spools as necessary. Test procedure shall be approved by P.I.U.

6.

DEFINITIONS
SATIP: Saudi Aramco Typical Inspection Plan
SAIC: Saudi Aramco Inspection Checklists.
SATR: Saudi Aramco Test Record.
Above Ground Piping:
Any piping entirely or partially running Above Ground shall be covered by this
procedure for Above Ground portion.

7.

PROCEDURE
7.1.

Receiving Inspection
7.1.1.

Materials shall be in accordance with the specifications and

Client Requirements and from approved sources. All materials
supplied shall be subject to the prior approval of the Client
Representative, when required. Materials shall be inspected
in accordance with the applicable SATIP and
procedure,
QWI 155.

C.A.T. GROUP QUALITY ASSURANCE

7.2.

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

Field, Shop Fabrication Inspection

7.2.1.

Responsibility for field shop inspection rests primarily with

the QC Inspector and Shop Fabrication Foreman .

7.2.2.

All fabrications shall be constructed in strict accordance with

the pipe spool drawings and contract specifications, except
overall fabrication length which may be adjusted to
accommodate handling capabilities, all shop fabrication will
be in accordance with specification, SAES-W-011, and the
Relevant Code.

7.2.3.

Preheating
7.2.3.1.

7.2.4.

7.2.5.

Extent of preheating requirements shall be as

noted for each pipe material line class in SAESW-011 Tables 4A, 4B, 5A, 5B, and shall normally
be accomplished by means of local fuel firing or
electric resistance.

Prior to welding, the following should be checked:

7.2.4.1.

Fit-up.

7.2.4.2.

Welders are familiar with and understand the

requirements of the relevant W.P.S.

7.2.4.3.

Use of proper material and electrode for specific

line class.

7.2.4.4.

Check condition of electrodes.

7.2.4.5.

Material to be welded must be free of dirt, rust,

scale, or any foreign debris.

All fabrication shall be checked for the following:

7.2.5.1.

Adherence to welding procedure for material

classification.

7.2.5.2.

Dimensional accuracy.

7.2.5.3.

General configuration. (Check Orientation of

hand-wheels on welded valves, branch
connections, instrument connections, etc.)

7.2.5.4.

Line number identification.

7.2.5.5.

Piece mark number (numbering sequence shall

be determined by the field shop).

C.A.T. GROUP QUALITY ASSURANCE

7.3.

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

7.2.5.6.

Conformance to
specifications.

material

and

fabrication

7.2.5.7.

That all welds are properly identified with

welders symbol.

7.2.5.8.

Threaded joints which are to be seal welded do

not have thread compound or tape applied to
threads, and that seal welds of thread joints
completely cover exposed threads as per SAESL-110.

7.2.5.9.

Socket welds are fit-up with proper gaps

between end of pipe and bottom of socket.

Pre and Post Weld Inspection of Spool

QC inspector shall record relevant details on checklists identified in
SATIP-W-011-01, Approval and signature of the checklist shall release
the spool for NDE.
NDE shall be executed as per Client Approved Procedure SATIPNDE-RT-01, SATIP-NDE-MPI-01, SATIP-NDE-UT-01,SATIP-NDELPT-01 and SAES-W-011. Each type of NDE shall have its respective
report forms.
After NDE completion, details and report numbers shall be entered
onto the respective checklist. At this stage, the spool shall be released
for painting, erection and pressure test.

7.4.

Painting of Spools
Painting of pipe spools shall be carried out as per Procedure P143,
Painting Procedure and the relevant APCS.

7.5.

In Process Inspection and Testing For Field Fabrication and Erection of

Above Ground Pipe
7.5.1.

Responsibility for field fabrication and erection inspection

rests primarily with the QC Inspector and Discipline
Foreman.

7.5.2.

Fabrication and erection shall be in strict accordance with

the fabrication specification and the pipe spool drawings.
The piping arrangement drawings shall be used in those
cases where the line will not be spooled.

7.5.3.

Ensure that welding operations being performed in areas,

which are subjected to the elements, are properly protected
from wind, dust, rain, etc.

C.A.T. GROUP QUALITY ASSURANCE

7.5.4.

Check preheating requirements as noted in Section 7.2.3.

7.5.5.

All fabrication shall be checked for the following:

7.5.6.

7.6.

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

7.5.5.1.

Adherence to welding procedure and Standard.

7.5.5.2.

Dimensional accuracy.

7.5.5.3.

General configuration.

7.5.5.4.

That all welds are properly identified with welders

symbol.

7.5.5.5.

Material code markings to ensure usage of

correct pipe, fittings, and other components.

Items which require special attention are:

7.5.6.1.

Valves which must be mounted with special flow

direction such as check valves, control valves,
globe valves, diaphragm valves, valves which
divert flow in more than one direction, etc., and in
special cases ball valves and plug valves.

7.5.6.2.

Correct installation and type of flange gaskets and

bolts.

7.5.6.3.

Strainer and traps, which must be installed with

proper flow direction.

7.5.7.

NDE should be conducted at grade prior to line erection

whenever possible.

7.5.8.

Prior to erection, lines should be internally inspected, where

possible, to ensure a system free of debris.

Radiographic Inspection
QA or QC Manager shall submit Radiographic Inspection Procedure
to Client Representative. Radiographic activity will start only after
procedure is approved. Forms and proper files shall be prepared for
keeping records.
Amount of NDE will be as per SAES-W-011 and Relevant Code
Welds shall be radiographed; films processed and interpreted, reports
are submitted and records are kept in files. Rejected weld by C.A.T.
QC Personnel or by Client shall be repaired and re-radiographed or
cut out if Client Representative believes necessary,

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

The QC Manager will submit to Client Representative, as required, a

report of the welder symbols of all welders responsible for weld
defects.
The report will identify the welder symbol, number of weld defects by
welder, total weld defects in the last fifty joints welded and total weld
defects he has been responsible for on the job.
This report will be done for both line and fabrication production
welders.
7.7.

Pressure Testing of Spools:

7.7.1.

Pressure testing of piping is planned well in advance of

fabrication and Test Packs are prepared. Testing is carried
out in accordance with Client Approved Hydrostatic Test
Procedure

7.7.2.

Hydrostatic Test Pack

Format and contents of Test Packs will be discussed with
client and finalized well in advance of any testing in order that
packs can be systematically built as work progresses.

7.7.3.
7.8.

Pipe Supports
7.8.1.

7.9.

As per approved Test Pack, test is prepared and carried out.

All documentation in the Test Pack is recorded and signed.

The QC Supervisor shall ensure that all required pipe

supports are properly prepared, coated and inspected with
the appropriate documentation in accordance with the
applicable procedure, P149, Inspection and Testing
Procedure for Structural Steel Works and P133, Inspection
and Testing Procedure for Concrete Works.

Piping Completion and Inspection (Punch Out)

7.9.1.

Organization
A completion / Inspection team should be organized and
ready to function when the first system is reported 100%
erected.
The team should include, but not necessarily be limited
to:
Discipline Engineer
Discipline Foreman
QC Inspector.
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C.A.T. GROUP QUALITY ASSURANCE

7.9.2.

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

Responsibility

The ultimate responsibility for effective control of piping

completion rests with the Discipline Engineer.

It is recognized that job conditions may vary and

therefore some of the outlined duties may be delegated
to other individuals as seen fit by the Discipline Engineer.

7.10. Pressure Testing

7.10.1.

Field pressure testing of piping systems and integral

components shall be in strict accordance with SAES-L-150,
SAES-A-004, SATIP-A-004-01, SATIP-A-004-02, SATIP-A004-05, Approved Test Procedure and S.I.S.

7.10.2.

Preparation of Field Test Packages

7.10.2.1.

At the earliest date possible, the Discipline

Engineer shall review the pressure test flow
diagrams to determine test systems and their
availability. Test systems may require rearrangement if incomplete items within a system
will cause a delay in testing.

7.10.2.2.

When arranging a test system, care must be

taken not to exceed the maximum allowable test
pressure of any component within the system.

7.10.2.3.

Test preparation

7.10.2.3.1. The Discipline Engineer shall inspect each

piping test system. The purpose of this
inspection is to ascertain that each piping test
system is in fact ready for test. Items which
normally present problems and should be
checked are:
a) Pressure source and test gauge should
be upstream of check valve. Otherwise
check valve should have flapper removed
or jacked-up, Ensure that test blinds
installed are the correct rating.
b) Ensure that all items such as control
valves, relief valves, rupture discs, orifice
plates, expansion joints, etc. which could
be damaged during pressure test have
been removed or isolated,
9

C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

7.10.2.3.2. Any deficiencies found during this inspection

should be listed using a punch list form and
should be forwarded to the Project Manager
for immediate action.
7.11. Testing
The Discipline Engineer shall prepare all piping systems ready for
pressure test in accordance with applicable specifications.
7.11.1.

Test pack should be completed; forms filled in and signed in

order to release the piping system for test.

7.11.2.

QC Inspector shall punch out each system against the

isometrics to ensure its completeness.

7.11.3.

The QC Manager shall inform Client about the Hydrostatic

Testing operation schedule using an R.F.I.

7.11.4.

The Discipline Engineer shall verify that all instruments are

calibrated according to relevant SATIP and SAES-A-004.

7.11.5.

The hydro testing operation shall start and proceed in

accordance with approved procedure
7.11.5.1.

8.

All test documentation, hydro test report

instruments calibration sheets, and pressure and
temperature recordings shall be kept in a
separate file at QA/QC Office.

RECORDS
All records relevant to above procedure shall be maintained at the site office for the
duration of the project and repatriated, to the area head office to be archived, and
kept for a period of Three years, following the achievement of the project.

9.

REFERENCES
SAES-W-011 & 12.
SAES-L-150.
SAES-A-004
SAEP 1142
SATIP-A-004-01 / 03 & 05.
SATIP-L-108-01
SATIP-L-350-01 / 02 /07 / 08
SATIP-M-001-01
SATIP-NDE-RT-01
SATIP-NDE-MPI-01
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C.A.T. GROUP QUALITY ASSURANCE

INSPECTION AND TESTING FOR ABOVE GROUND PIPING WORKS

REVISION 0 DATED 20.04.2014

SATIP-NDE-UT-01
SATIP-NDE-LPT-01
SATIP-W-011-01
SATIP-W-012-01
10. ATTACHMENTS
None

11