Piping Fabrication and Construction

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Piping Fabrication And Construction
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Piping & Valves

File Reference: MEX10108
For additional information on this subject, contact

K.S. Chu on 873-2648 or R. Hingoraney on 873-2649
Piping & Valves

Piping Fabrication & Construction
CONTENTS
PAGE
DETERMINING WHETHER PIPING MEETS FABRICATION REQUIREMENTS.....1

Material Limitations.....................................................................................................1
Pipe ..............................................................................................................................1
Pipe Nipples.................................................................................................................2
Flanges.........................................................................................................................3
Pipe Fittings .................................................................................................................3
Drawings......................................................................................................................4
Fitup Tolerances ..........................................................................................................4
Mitered Joints ..............................................................................................................5
Ends for Field Welding................................................................................................5
Pipe Bending................................................................................................................5
Cold Bending...............................................................................................................8
Hot Bending.................................................................................................................9
Sample Problem 1......................................................................................................10
Solution......................................................................................................................12
Welding and Heat Treatment .....................................................................................13
Butt-Welds.................................................................................................................14
Fillet Weld .................................................................................................................18
Welding Steps............................................................................................................18
Inspection and Testing of Pipe Spools.......................................................................22
Product Marking and Preparation for Shipment ........................................................22
Identification..............................................................................................................22
Cleaning.....................................................................................................................23
Painting......................................................................................................................23
Protection...................................................................................................................23
Piping & Valves

DETERMINING WHETHER METALLIC PLANT PIPING

MEETS INSTALLATION REQUIREMENTS...............................................................24
Storage and Handling ................................................................................................24
Pipe Fitup and Tolerances .........................................................................................25
Alignment of Pipe Attached to Load-Sensitive Equipment .......................................26
FLANGE JOINT ASSEMBLY..................................................................................27
Cleaning.....................................................................................................................32
Buried Installation......................................................................................................32
Sample Problem 2......................................................................................................33
Solution......................................................................................................................33
DETERMINING WHETHER ABOVEGROUND AND BURIED PIPING MEET
INSTALLATION REQUIREMENTS.............................................................................35
Vertical Profile...........................................................................................................35
Elastic Bends .............................................................................................................36
Preformed Bends .......................................................................................................36
Preformed Bends for Aboveground Pipelines ...........................................................37
Preformed Bends for Buried Pipelines ......................................................................38
Storage and Handling ................................................................................................38
Installation of Aboveground Pipelines.......................................................................39
Installation of Buried Pipelines..................................................................................40
Tie-in Temperature ....................................................................................................41
Cleanup and Records .................................................................................................42
WORK AID 1: PROCEDURE FOR DETERMINING WHETHER
PIPING MEETS FABRICATION REQUIREMENTS ...................................................45
WORK AID 2: PROCEDURE FOR DETERMINING WHETHER
METALLIC PLANT PIPING MEETS INSTALLATION REQUIREMENTS...............50
WORK AID 3:PROCEDURE FOR DETERMINING WHETHER
ABOVEGROUND AND BURIED PIPELINES MEET
INSTALLATION REQUIREMENTS.............................................................................51
GLOSSARY ....................................................................................................................52
Piping & Valves

Determining Whether Piping Meets Fabrication Requirements

If a system is not fabricated with reasonable quality, the design assumptions will not be met,
and problems can occur during construction and subsequent operation. For example, forcing
pieces of the system together imposes loads that were not accounted for in the original design.
These loads could lead to system reliability and maintenance problems, and eventual failure in
extreme cases. Saudi Aramco standards SAES-L-050, SAES-L-051, and 01-SAMSS-010
provide the requirements that ensure a piping system is fabricated properly. For example, the
standards give welding requirements for fabrication that specify criteria, such as matching
diameter, angularity, and material. The Saudi Aramco engineer must examine the contractor's
work to confirm that tolerances and other fabrication requirements meet the standards. Work
Aid 1 summarizes these fabrication requirements.
Material Limitations
Compatible materials are essential for piping fabrication. All materials that are used for
piping elements or structural attachments must conform to a listed specification in accordance
with ASME/ANSI B31 Codes, and shall be traceable to mill certificates. This ensures that
basic material quality conforms to recognized specifications, and that confirming
documentation is supplied for the materials that are actually used. 01-SAMSS-010 provides
specific additional material requirements for fabrication. These are summarized as follows.
Pipe
Pipe for plant applications shall be seamless or single-longitudinal seam submerged arcwelded (MEX 101.02) and conform to one of the following:
-
API Spec 5L, Grade B through X60.
ASTM A53, Seamless Grade B, black.
ASTM A106, Grade B.
These specifications are all readily available and result in pipe of comparable strength.
Piping & Valves

Pipe for cross-country pipelines shall conform to one of the following:

-
Electric Resistance Welded (ERW) pipe in accordance with 01-SAMSS-033, API

5L Electric Welded Line Pipe.
Spiral-welded pipe in accordance with 01-SAMSS-035, API Line Pipe.
If 01-SAMSS-035 pipe is not available, API 5L or ASTM A106 pipe may be used
provided it meets the chemical composition and hardness test requirements that are
specified in 01-SAMSS-035.
For wet, sour service, the pipe must be seamless and conform to 01-SAMSS-016, Sour,
Wet Service Line Pipe.
Pipe Nipples
Nipples shall conform to one of the pipe specifications previously listed, and shall be
Schedule 80 minimum thickness. This minimum thickness is required regardless of the
design conditions and is specified to ensure that these small diameter nipples have
adequate strength to resist mechanical damage that could occur in the shop or field. If
threading is required, it must be a taper pipe thread in accordance with ANSI B1.20.1,
Pipe Threads, General Purpose (inch).
Piping & Valves

Flanges
Weld-neck flanges and blind flanges that conform to one of the following must be used unless
otherwise specified in the purchase order.
ASME/ANSI B16.5 using ASTM A350, Grade LF2 normalized material.
02-SAMSS-011.
Saudi Aramco Standard Drawing attached to the purchase order.
MSS-SP-44 when not specified by either B16.5 or Saudi Aramco Standard Drawings.
Here again, basic material strength and quality levels are being established for standardization
purposes. The strongest flange type, i.e., a weld-neck, is being specified to avoid any
additional design consideration necessary for slip-on or lap-joint-type flanges. However,
remember that general flange type and material selection requirements are governed by
SAES-L-009 and 02-SAMSS-011 (as discussed in MEX 101.04), and may differ from what is
stated here for specific cases.
Pipe Fittings
Butt-welded fittings shall be used for nominal pipe sizes 50 mm (2 in.) and larger, and
conform to 02-SAMSS-005. Material grade and nominal wall thickness shall be the
same or equal to the adjoining pipe.
Forged steel threaded or socket-welded fittings shall conform to ANSI B16.11, pressure
class 3000, ASTM A105, and unions shall conform to MSS-SP-83. While class 2000
fittings are available, this requirement specifies a stronger fitting as the base case.
Threaded or socket-welded fittings can only be used for pipe sizes smaller than 50 mm
(2 in.). However, the size may include 50 mm (2 in.) NPS for minor field repairs or
maintenance.
Forged steel welding bosses shall conform to either Aramco Standard Drawing AE036175 or AE-036643 or equivalent forged steel welding outlets, ASTM A105, pressure
class 3000 minimum. These must abut the pipe wall and be attached with a fullpenetration weld. They may only be used for NPS 50 mm (2 in.) or smaller.
Piping & Valves

Drawings
Fabrication drawings are provided to the contractor for fabrication work. These drawings
specify piping component materials, dimensions, and specific tolerances for piping
fabrication. The Saudi Aramco engineer needs to check that the drawings conform to all
fabrication requirements, and that these are also being followed in the field.
The vendor shall prepare the detailed shop fabrication drawings.
Any details not shown on the buyer's drawings shall be designed by the vendor in
accordance with the applicable ASME/ANSI B31 Code.
Welded branch connections and other joints shall be full-strength reinforced such that
the MAOP of a pipe spool shall be as limited by either the specified pipe or the flange
rating. In this way, branch reinforcement will not be the limiting factor in setting the
piping system MAOP, and would not need to be considered in any potential future
projects to increase system design pressure.
Standard piping symbols that are used on Piping Detail Sheets and Isometrics are
identified on Standard Drawing AB-036227.
Fitup Tolerances
Fitup tolerances specify the allowable limits that are placed on mismatch between sections of
piping. These tolerances are established to limit any extra load that is placed on the piping
system or connected equipment, and to provide greater assurance of obtaining acceptable
weld quality. Fitup tolerances apply to all pipe fabrication.
Established tolerances control the fabrication of the pipe spool in the shop, and ultimately the
assembly of multiple spool pieces in the field to make up a complete piping system. Normal
practice is to maximize the amount of shop fabrication to bring the largest possible spool
pieces to the field for final assembly. This minimizes the amount of work to be done in the
field. The Saudi Aramco engineer must ensure that the specified fitup tolerances are applied
to a contractor's work. 01-SAMSS-010 provides these tolerances for fabricated pipe sections,
as summarized in Work Aid 1. The fitup tolerances required for the installation of plant
piping are in SAES-L-050 and will be discussed later in this module.
Piping & Valves

Mitered Joints
Mitered joints are changes in direction that are obtained by welding short pipe sections
together. Mitered joints with angular offset larger than 3 are not permitted unless
specified on the buyer's drawing.
A welding technique shall be used which provides a smooth, regular, and fully
penetrated internal surface. This, plus the detailed design specified for the miter,
ensures that it will be as strong as the straight runs of connected pipe.
Ends for Field Welding
All welding ends shall be beveled with an angle of 35, plus or minus 5, and a root face
of 1.5 mm (1/16 in.). The bevels shall be machine-cut bevels or smooth, clean, slag-free
flame cut. The end plane shall be normal to the pipe axis as defined on the piping
drawing, within 0.25. In this way, spool-piece weld ends are already prepared for
welding in the field, when required.
Pipe Bending
A bend is a change in direction that is made by physically bending a straight section of pipe,
rather than by using a wrought or forged elbow. Pipe bends are prefabricated, or done by the
contractor, and need to be checked by the Saudi Aramco engineer. Bending is normally done
when a long, gradual change in direction is required, either because of fluid flow
considerations, the local terrain for pipeline applications, or to permit pipe scraping.
Bends shall be completely free from buckles, dents, cracks, wrinkles, other mechanical
damage or indentations such as could be caused by the grips of the bending machine.
These could act as localized stress-concentration points or obstructions to pipe scrapers.
Flat spots shall have no dimension exceeding the value given by the following formula:
d =
2 tD
where: d = Largest dimension of the flat spot

t = Nominal wall thickness
D = Nominal pipe diameter
Larger flat spots could cause higher local stresses or obstruct pipe scrapers.
Piping & Valves

The difference between the largest and smallest diameter (flattening) of the cross-section
shall not exceed 5% of the nominal pipe diameter at any point in the bend, nor 3% of the
nominal pipe diameter at the ends. A larger difference could cause excessive local
stress, make the bend more prone to buckling, or obstruct passage of a scraper.
The minimum wall thickness shall not be less than the minimum allowed wall thickness
of the pipe. Some pipe thinning will occur during the bending process. This
requirement ensures that the bend will not limit the MAOP of the system.
Unless otherwise specified, the centerline radius of pipe bends shall be at least five times
the nominal pipe diameter (5D). This will minimize local stresses in the bend.
When bends are supplied with welding ends for field welding, a minimum straight
tangent length of the smaller of 1 1/2 times the nominal pipe diameter or 600 mm (2 ft.)
shall be provided at each end. This will provide easier access for welding at the bend.
Bend tolerances shall be as follows (unless otherwise specified):

-
0.5 on bend angle.
1% on bend radius.
These points are illustrated in Figure 1.
Piping & Valves

TOLERANCES AT PIPE BENDS
Notes
(E-C) 0.05D at any point, 0.03D at ends
A 5D
B 1.5D or 600 mm (2 ft.), based on smaller value
Bend Minimum Thickness Not Less Than Straight Pipe Minimum Allowable
Thickness
Bend Tolerances: 0.5 on angle, 1% on radius
FIGURE 1
Piping & Valves

Cold Bending
Cold bending is normally done on tubing and on pipe with relatively small diameters and wall
thicknesses. Proper equipment and dies are essential to avoid wrinkling, excessive thinning,
and excessive ovality. Saudi Aramco requires that:
Cold bends shall be made below 649C (1,200F), and seamless, Grade B pipe shall be
used. The temperature shall be below 316C (600F) if pipe material that has been
strengthened by cold work is used (such as the "X" grades of the API 5L specification).
Using a higher bending temperature with a cold-worked material will reduce the
material strength.
For pipe that is 150 mm (6 in.) and larger in outside diameter, cold bends shall not be
used unless they were specified in the Purchase Order, and have at least a 10D bend
radius.
For cold bends with a radius of less the 30D, the nominal outside diameter divided by
the nominal wall thickness shall not exceed 35.
For wet, sour service, cold bends to a radius of 5D or less shall be heat treated at 593649C (1,100-1,200F) for one hour per 25 mm (1 in.) nominal wall thickness, but not
less than one hour.
For wet, sour service, a hardness measurement shall be made on each bend at the outer
radius of the bend area. The maximum hardness is limited to 237 Brinell. Limiting the
hardness level at the maximum stress point of the bend minimizes the probability of
cracking in this service.
Piping & Valves

Hot Bending
Pipe hot bending may be done either in a furnace, or by passing the pipe through an induction
heating coil. 01-SAMSS-010 specifies general requirements for hot bending, and specific
requirements for both the furnace and induction methods. The following highlights several of
these requirements. Participants are referred to 01-SAMSS-010 for additional details.
Detailed procedures must be submitted for review and approval by the Consulting
Services Department.
Impact test requirements are specified for low-temperature service [below -18C (0F)].
Hardness measurements and acceptance criteria are specified. This will ensure that the
bending procedure did not produce any locally hard areas that would be more prone to
cracking.
Wall thickness measurements must be made along the bend to ensure that excessive
thinning did not occur.
Pipe material and bending temperature requirements are specified for furnace hot bends.
Procedural requirements are specified for induction bends.
Piping & Valves

Sample Problem 1
This sample problem will review what has been discussed thus far regarding fabrication and
installation of plant piping systems. Work Aid 1 may be used to help solve this problem.
A contractor has been engaged by Saudi Aramco to fabricate and install a piping system at a
new pump. There have been reports from the field that pipe fitup and pump alignment have
not been going smoothly. Field personnel have expressed concern that the fabrication and
installation quality is not good. You have been asked to begin reviewing the situation.
Figure 2 is a representation of a fabrication drawing for one portion of the piping system.
Your intent is to use this as a sample to see if further review of the contractor's work is
necessary. In addition to this, flange alignment measurements were made in the field at the P602 suction flange. The following misalignments were measured:
Vertical bolt-hole offset
+1.5 mm (+ 1/16 in.)
Horizontal bolt-hole offset
-0.8 mm (- 1/32 in.)
Rotational offset
Flange-face tilt across diameter
+2.4 mm (+ 3/32 in.)
Flange-face separation
+1.5 mm (+ 1/16 in.)
+0.4 mm (+ 1/64 in.)
No deviations or additions from 01-SAMSS-010 were permitted by the original purchase

specification. Use 01-SAMSS-010, SAES-L-050, and Work Aid 1 to assist in your review.
10
Piping & Valves

FABRICATION DRAWING
Dimensions
A = 37'6" 1/4"
B = 13'-4" 1/8"
C = 22'-0" 1/8"
D = On Pipe Centerline 3/16"
E = 96" Bend Radius
Notes
-
Pipe: A106, Gr. A, 16 in., Sch 40.

Nipples for Vents and Drains: 3/4 in., Sch 40, A106, Gr. B.
Weld-Neck Flanges: ASME/ANSI B16.5, Class 300, A350 LF2.
Butt-Weld Fittings: A234, Gr. WPB.
3/4 in. Forged Couplings for Vents and Drains: ANSI B16.11, Class 2000, A105
Conform to ASME/ANSI B31.3 and 01-SAMSS-010
FIGURE 2
11
Piping & Valves

Solution
1.
The fabrication drawing shows the pipe material to be A106, Gr. A. This is not an
acceptable material per 01-SAMSS-010. It should be A106, Gr. B, or one of the other
acceptable pipe material specifications.
2.
The nipples are specified to be A106, Gr. B material, which is acceptable. However,
their wall thickness is specified as Sch. 40. They should be Sch. 80 minimum per 01SAMSS-010.
3.
The flanges are specified to be weld-neck, ASME/ANSI B16.5, Class 300, A350 LF2
material. This is acceptable.
4.
The butt-weld fittings are specified to be A234, Gr. WPB. This is acceptable.
5.
The forged couplings are specified to be A105 material, ANSI B16.11, Class 2000.
They should be Class 3000 per 01-SAMSS-010.
6.
A note indicates that the fabrication conforms to ASME/ANSI B31.3 and 01-SAMSS010. Based on previous information, this is not in conformance with at least 01SAMSS-010 requirements.
7.
The dimensional tolerances should conform to 01-SAMSS-010 and SAES-L-050.

Dimensions B & C conform to the required 1/8 in. tolerance.
Dimension A has a + 1/4 in. tolerance and is not acceptable.
Dimension D indicates the flanged branch connection can be off the pipe centerline by
3/16 in. It should have a 1/16 in. tolerance.
The bend radius of 96 in. is acceptable since it exceeds the minimum of five times
(Nominal Pipe Diameter) required by 01-SAMSS-010.
8.
The flange alignment tolerances generally exceed the 1/64 in. maximum misalignment
tolerance specified in SAES-L-050, since several exceed the maximum 1/64 in.
permitted.
12
Piping & Valves

In reviewing this one fabrication drawing, a large number of relatively serious fabrication and
construction discrepancies were found. The fabrication and erection tolerances do not
conform to Saudi Aramco requirements. Therefore, it should not be surprising that there are
problems in the field with the installation. In addition, several material and piping component
design deficiencies were also noted. Because of all these deficiencies, a complete design
review of the contractor's work is warranted.
It should be noted that this review was only made on the basis of conforming to the minimum
Saudi Aramco requirements for fabrication and erection. It was not a design review. For
example, it was tacitly assumed that Class 300 flanges and Schedule 40 thickness for the 16
in. pipe were acceptable for the design conditions. A complete design review would at least
spot check these items, as well, at some point during project execution.
Welding and Heat Treatment
Welding is one of the primary ways of joining pipe. Welded joints represent the ultimate in
safety and reliability. All codes call for welding to be carried out using a qualified procedure
and welders. Included in the standard procedure are: base-metal specifications, electrode,
joint preparation, weld position, welding process (including whether it is manual or
automatic), techniques, electrical details, preheat and interpass temperatures, and post-weld
heat treatment requirements. The Saudi Aramco engineer needs to check how the contractor
plans to weld pipe together. This requires knowing the primary welding types and where they
are typically employed in piping systems. 01-SAMSS-010 and the applicable ASME/ANSI
B31 Code provide considerations for heat treatment and the two primary weld types used:
butt welds and fillet welds. Saudi Aramco welding requirements are specified in the
following SAES's:
SAES-W-001, Basic Welding Requirements.
SAES-W-011, Welding Requirements for On-plot Piping.
SAES-W-012, Welding Requirements for Pipelines.
13
Piping & Valves

Butt-Welds
Butt-welds are made between two components whose edges are in close proximity. Buttwelded joints in piping systems are primarily of the single-V configuration and are welded
from the pipe outside surface. Larger diameter pipes which can be accessed from the inside
will often be welded from both sides using a double-V type of joint preparation. The joint
preparation and the procedure that is used ensure that there is complete fusion between the
edges of the components being joined. Joint designs shown in Figure 3 or applicable
combinations of these joint design details are typically used for ends of equal thickness. The
transition between ends of unequal thickness may be accomplished by taper grinding the
thicker pipe to match the thinner, or by using weld metal to provide a smooth transition as
shown in Figure 4. A prefabricated thickness transition section of not less than one-half pipe
diameter in length is another means to make the change between pipe thickness. Butt-welds
will always be used to weld pipe ends together, to weld butt-weld-type flanges or fittings to
pipe ends, or to weld the edges of formed plate together when plate is used to manufacture
pipe.
14
Piping & Valves

ACCEPTABLE BUTT-WELDED JOINT DESIGN FOR

EQUAL WALL THICKNESS
Source: ASME/ANSI B31.4 - 1989. With permission from American Society of Mechanical Engineers.
FIGURE 3
15
Piping & Valves

ACCEPTABLE BUTT-WELDED JOINT DESIGN FOR

UNEQUAL WALL THICKNESS
FIGURE 4
16
Piping & Valves

FILLET WELDS
FIGURE 5
17
Piping & Valves

Fillet Weld
The fillet weld generally requires no special preparation of the joints. It is an angular weld
bead that joins components positioned normally at a 90 angle to each other. Fillet welds may
be concave to slightly convex in shape. The size of a fillet weld is stated as a leg length of the
largest inscribed right isosceles triangle as shown in Figure 5 covering typical attachment
details of slip-on flanges. In piping systems, fillet welds are only used for slip-on flanges,
socket welds, and for welding attachments to piping components (e.g., reinforcing pads,
supports, etc.).
Welding Steps
The following outlines the overall steps that are required for welding.
Preparation for Welding - Procedure and Welder Qualification:
Before any welding is done, the specific details of how it will be carried out, i.e. the
welding procedure, must be specified and demonstrated to achieve acceptable results. A
welding procedure is as important to the welder as a blueprint or drawing is to a
machinist. Each of the ASME/ANSI B31 Codes, plus modifications contained in SAESW-001 (and SAES-W-011 or SAES-W-012 as applicable), specify welding procedure
qualification requirements.
Welding procedure qualification demonstrates that the approach specified for doing the
weld will achieve acceptable results when properly applied. The next step is to qualify
the particular welders and welding equipment to carry out the specific welding
procedure. Here again, the relevant ASME/ANSI B31 Code plus Saudi Aramco
requirements must be met.
The end result of these two steps is that both the welding procedure, and the individuals
and equipment executing it, have been confirmed to produce acceptable results.
18
Piping & Valves

Cleaning:
Internal and external surface to be thermally cut or welded shall be clean and free from
paint, oil, rust, scale, or other material that would be detrimental to either the weld or
base metal when heat is applied. If such items are not cleaned, they could mix with the
weld metal at elevated temperatures and result in poor quality welds.
End Preparation:
The ends of the components to be welded must be set to the correct geometric shape
suitable for the materials, wall thickness, and welding process involved.
End preparation is acceptable only if the surface is reasonable smooth and true, and slag
from oxygen or arc cutting is cleaned from thermally cut surfaces. Discoloration that
remains on a thermally cut surface is not considered to be detrimental oxidation.
Component ends may be trimmed to allow for fitting a backing ring, provided that the
remaining net thickness of the finished ends is not less than the minimum required wall
thickness for the service conditions. A backing ring is often placed at the inside surface
of pipe sections to be joined by butt-welds to assist in achieving full penetration and
fusion.
It is permissible to size pipe ends to be of the same nominal size to improve alignment if
wall thickness requirements are maintained.
Where necessary, weld metal may be deposited inside or outside the component to
permit alignment or provide for machining to ensure satisfactory seating of rings or
inserts.
19
Piping & Valves

Preheating is used, along with heat treatment, to minimize the detrimental effects of high
temperature and severe thermal gradients that are inherent in welding. The necessity for
preheating and the temperature to be used shall be specified in the engineering design and
stated by procedure qualification. Specific preheat temperature requirements are specified in
the appropriate ASME/ANSI B31 Code based on the pipe material and wall thickness that are
being joined.
The following identifies specific benefits of preheating:
Dries the metal and removes surface moisture which could, if present, result in porosity
of the weld metal.
Reduces the temperature difference between the base metal and the weld to reduce the
cooling rate of the weldment, lowers the weld hardness to reduce residual stresses, and
reduces cooling/shrinkage stresses.
Helps maintain the weld pool molten for a longer time to permit maximum fluxing and
separation of impurities.
Helps drive off absorbed gases (such as hydrogen) which could contribute to weld
porosity.
20
Piping & Valves

Postweld-heat treatment is used to avert or relieve the detrimental effects of high temperature
and severe temperature gradients that are inherent in welding, and to relieve residual stresses
that are created by bending and forming. Specific heat treatment temperature and procedure
requirements are specified in the appropriate ASME/ANSI B31 Code based on the pipe
material and wall thickness being joined.
The following summarizes the principal reasons for PWHT:
Stress relief is the most common reason for specifying PWHT, and is the only
consideration for the requirements that are specified in the ASME/ANSI B31 Codes.
Residual stresses will remain in the pipe and result from shrinkage as the weld and
adjacent pipe metal cool down from elevated welding temperatures. Residual stresses
will also remain after bending or forming processes. If these residual stresses are too
high, they can lead to premature failure of the pipe. ASME/ANSI B31 Code
requirements specify when PWHT is required to relieve these residual stresses and bring
the pipe to an initial stress-free state. PWHT is also required to reduce fabrication
stresses to minimize the potential for stress-corrosion cracking in certain process
environments, such as caustic, amines, and wet H2S.
After welding the normal grades of stainless steels (i.e., those that are not stabilized with
alloy additions), it is necessary to heat treat the material to restore maximum corrosion
resistance.
PWHT is required to prevent caustic embrittlement of welded carbon steel pipe that
handles alkaline solutions. Caustic embrittlement is a form of stress corrosion where the
residual stresses due to welding are sufficient to cause failure.
PWHT is also sometimes necessary to reduce weld hardness in certain materials.

Minimizing weld hardness reduces the tendency to crack, especially in certain process
environments such as caustic or wet H2S.
21
Piping & Valves

Inspection and Testing of Pipe Spools

When the pipe spool piece has been completely fabricated, it is ready for final inspection and
testing. The vendor shall give reasonably advanced notice regarding the dates that fabrication
and tests will be made. All materials, certificates, fabrication, testing, and examination shall
be in accordance with ASME/ANSI B31.3, Chapter VI, and are subject to verification by the
buyer's inspector.
When all openings on a pipe spool are either flanged or threaded, the spool shall be
hydrostatically tested. When no test pressure is indicated in the purchase order, the
hydrostatic test pressure shall be based on the flange rating per ASME/ANSI B16.5, but in no
case shall the pipe be stressed to more than 90% of the specified minimum yield strength
based on the nominal pipe thickness.
The vendor must provide the blind flanges, plugs and caps that are needed to close off open
spool piece ends. This prevents the entry of dirt and debris during transportation and
subsequent storage prior to field installation, and reduces the amount of cleaning and flushing
required in the field.
Pipe spools with welded ends shall not be pressure tested unless specified in the purchase
order. In these cases, the spools will be tested in the field after the entire piping system has
been assembled.
Product Marking and Preparation for Shipment
In order to properly assemble the piping spools in the field, the vendor must properly identify
and prepare each segment for shipment.
Identification
Each spool shall be marked with the spool mark number painted at the ends as shown on
the drawings. The numbers shall not be less than 25 mm (1 in.) in height.
The spool number will be die-stamped on the rim of each flange.
Pipe bends that are delivered as separate components must also be marked, as specified
in 01-SAMSS-010.
22
Piping & Valves

Cleaning
All loose, foreign material and weld spatter shall be removed. The spool shall be clean
and dry.
Painting
Unless specified otherwise, spools shall not be painted or coated.

Protection
When spools are supplied with blind flanges, the latter shall be bolted on with the
specified gaskets and stud bolts. Other flange faces shall be protected by a cover that is
bolted to the flange.
Threaded pipe ends shall be provided with steel or malleable iron pipe caps.
Threads shall be coated with a graphite and oil paste.
Welding ends shall be protected by a securely fastened bevel protector.
23
Piping & Valves

Determining Whether Metallic Plant Piping Meets Installation Requirements

The piping fabrication requirements that were discussed in the previous section apply
primarily to carbon steel piping, but may be used for alloy piping as well, with some
modifications. For plant piping, there are additional piping fabrication requirements that the
engineer must be able to identify when auditing a contractor's work. These requirements are
outlined in SAES-L-050, which supplements ASME/ANSI Code B31.3. This section
discusses some of the requirements that are established in ASME/ANSI B31.3 and SAES-L050. These requirements are highlighted in Work Aid 2.
Storage and Handling
Improper handling and storage of pipe materials and welding filler metals can cause damage
and result in poor construction quality and failures during operation.
Pipe shall not be stored directly on the ground, and shall be placed on mounds or
sleepers. This will help prevent the accumulation of rainwater around the pipe, which
could result in corrosion.
Pipe shall not be stacked so high that pipes or their coatings may be damaged.
Fittings and valves shall be stored in shipping crates or on racks. This is to provide
greater protection from damage until these components are used.
End protectors shall be firmly attached to prevent damage to weld bevels, flange faces,
threads, or socket-weld ends.
Lined and coated pipes and fittings shall be lifted with wide fabric or rubber-covered
slings and padding to prevent damage. This prevents overly-localized load application
which could lead to excessive pipe deformation and damage to the lining or coating.
24
Piping & Valves

Pipe Fitup and Tolerances

Good joint fitup is essential to making a sound weld and minimizing the loads imposed on the
piping system and connected equipment. Depending on the welding process used, a slight
mismatch may be permissible. The applicable ASME/ANSI B31 Code specifies welding
requirements, which are supplemented by Saudi Aramco requirements. For example, in pipe
joints where the inside diameters have not been matched up by internal boring or tapering,
fitup may become a problem, particularly when backing rings are not used.
Pipe fitup for welded joints shall be as required by SAES-W-001, Section 7.
The tolerance for axial dimensions, face-to-face, center-to-face, and location of

attachments shall be 3 mm (1/8 in.) maximum.
Flattening of bends, measured as the difference between the largest and smallest outside
diameter at any cross-section, shall not exceed 5% of the nominal diameter of the pipe
(3% at the ends).
Lateral translation of branches and connections from centerline of run shall not exceed
1.5 mm (1/16 in.).
Flange bolt holes shall straddle the centerlines. Rotation of flanges, measured as the
offset between elevation of bolt holes on opposite sides of a flange centerline, shall not
exceed 1.5 mm (1/16 in.).
The tilt of flange measured at the periphery across any diameter shall not exceed 1 mm
(1/32 in.) from the square position.
25
Piping & Valves

Alignment of Pipe Attached to Load-Sensitive Equipment

As discussed in MEX 101.07, special care must be taken for load-sensitive equipment,
especially rotating equipment. Specifically, in attaching pipe to rotating equipment, the
installation should avoid putting excessive forces and moments on the machinery nozzles
which could result in misalignment. The flexibility calculations that were discussed in MEX
101.07 do not account for loads imposed on equipment nozzles during erection, and tacitly
assume that these will be relatively small. Adhering to relatively small installation tolerances
makes this a valid assumption.
Installation of piping that is connected to rotating equipment should preferably start at

the machine nozzle flange. This will reduce the possibility of having a large mismatch
between the pipe and machine flanges if pipe installation is begun from the opposite end
of the system. The first piping section up to the first flange should be loosely bolted to
the machine nozzle flange. Gaskets should be used during fabrication procedures and
renewed before final boltup. Temporary supports may be required during installation
until all pipe sections and permanent supports are installed.
Bolt on succeeding pipe sections as appropriate up to the first support. Adjust this
support as required to just contact the pipe at its bearing point before any temporary pipe
supports are removed. Proceed to any other adjacent supports which should be similarly
adjusted.
One or more field welds are typically used to join the piping nearest to the machine with
the rest of the system. The number and location of these field welds are determined
such that they will permit final position adjustments to achieve acceptable flange
alignment at the machine nozzle. The piping system should generally be freestanding
on its permanent support system without any additional support or restraint prior to
making these field welds. If this were not the case, additional loads could be imposed
on the machine nozzle when the temporary supports or restraints are subsequently
removed after making the field welds.
Spring supports should be locked in their cold position during pipe installation.
All spring supports will be adjusted in the locked position just until they contact their
respective support points. If spring-support adjustment is insufficient, modifications to
associated structural members or shimming will be required. Spring hangers should also
be locked and hanger rods adjusted until free movement is eliminated. Vertical flange
misalignment should never be corrected by using spring-support adjusters or springhanger rods.
26
Piping & Valves

Final bolt tensioning of component flanges close to the machinery should be done after
initial alignment of nozzle flanges.
Piping that requires any sections to be removed for flushing after completing field welds
should have final nozzle alignment and component flange boltup completed after
replacing flushed sections.
For piping over 75 mm (3 in.) NPS connected to machinery, flange alignment must be
within more stringent limits than is specified for general piping systems. More stringent
limits are required to minimize the loads that are imposed by flange boltup. These
flange alignment limits are summarized in Work Aid 1.
Precautions should be taken to prevent ingress of debris into machine internals during
construction of connecting pipework.
Spring supports are designed to support the weight of the pipe, insulation, and contents
during operation. Flange alignment is most easily accomplished with the spring locking
stops installed, which makes the spring a rigid support. Since alignment is being done
with the pipe empty, and the spring support was designed for the line full, trying to do a
pipe alignment with the spring stops removed could be an unreasonable exercise
(especially if the springs are designed for liquid loading during operation).
Flange Joint Assembly

Flange joint assembly procedures directly affect the ability of the flange to be leak-tight in
service. In many low-pressure, low-temperature, and/or nonflammable services, many rules
of good flanged joint design and makeup can and have been violated with no adverse
consequences. However, it is dangerous to break these rules in critical, high-temperature
services since the results can be serious leakage problems with consequent fires. The primary
factors for successfully making up a flanged joint and controlling leakage are the following:
Proper selection and design of the flanged joint.
Proper preparation, inspection, and installation of the flanged joint.
Identifying and controlling the causes of leakage.
Flanged joint assembly and leakage control are discussed below.
27
Piping & Valves

Preparation, Inspection, and Installation The following discusses the primary steps that are
required to achieve a properly assembled flanged joint. These are summarized in Work Aid
2.
Redo Damaged Surfaces Warped or badly corroded flanges should be replaced or

refaced. Flanges with tool marks or scratches across the gasket seating surface should
be refaced, since these form leakage paths.
Clean Faces All gasket and flange surfaces should be clean. Remove all burrs, rust,
and dirt from flange faces with scrapers or wire brushes. This step is often overlooked.
Align flanges Flanges at rest should be within the alignment tolerances previously
discussed, with the flanges practically mating before the bolts are installed. Nonparallel
flanges are sometimes straightened by applying heat or by bending the pipe. However,
the best alignment approach usually involves cutting off the flange and rewelding it to
the pipe.
Bringing the flanges into alignment should not leave any residual stresses in the piping
system. Residual stresses could lead to flange leakage in service or overload problems
in systems that are connected to load-sensitive equipment. This becomes more
important with increasing pipe diameter, as the residual stress increases with increasing
diameter for the same amount of misalignment.
Lubricate Threads and Nuts Lubricate the bolt threads and the nut faces where they
will contact the flange. An oil-graphite mixture works well. For high temperatures, use
high-temperature silicone grease or a colloidal copper compound. Lubrication helps
increase the amount of bolt load that goes into tightening the flange rather than into
overcoming friction. Lubrication also aids in achieving high enough and uniform bolt
tension required to achieve a leak-free joint during operation.
28
Piping & Valves

Place Gasket Properly The gasket must be centered on the flange faces to achieve a
reliable joint, but holding the gasket in place can be a problem. If something must be
used to hold the gasket, a high-temperature grease may be used sparingly in systems that
operate at less than 93C (200F). No grease, paste, or adhesive should be used to hold
gaskets for systems operating at 93C (200F) or more. The high temperature causes
these materials to burn off, which could damage the gasket and cause leakage.
Thin cellophane tape may be used on the outside edges of a gasket, but never on the
seating surfaces. Tape on the seating surfaces will deform the gasket during joint
assembly, burn out at operating temperature, and thus provide a leakage path. Centering
rings on spiral-wound gaskets help by allowing the gasket to be supported in the proper
position by a few bolts while the other bolts are inserted. Sheet gaskets should be cut so
that their outside diameter corresponds to the bolt position, again to help centering.
Use Proper Flange Boltup Procedure Flanges may be made up using a wrench and
hammer, an impact wrench, a torque wrench, or a stud tensioner. The most important
aspects of a proper boltup procedure, regardless of method, are to:
Use a "criss-cross" pattern bolt-tightening sequence, as is used when bolting a

wheel onto a car. Examples of such bolting patterns are shown in Figure 6. This
approach helps to achieve a uniform bolt load around the flange.
Use at least three rounds of tightening around the flange, increasing the applied
load in each round, with two rounds at the maximum load. This approach also
helps achieve uniform bolt load around the flange circumference.
For the most critical high-temperature or high-pressure flanges, use a method that
permits measuring the applied load (i.e., torque wrench or stud tensioner). In this
way, there is greater assurance that uniform bolt load is achieved. For such
applications, a maximum stud stress during boltup of 275-345 MPa (40-50,000 psi)
is the normal target.
29
Piping & Valves

Causes of Flange Leakage Most of the primary causes of flange leakage are directly related
to poor inspection or installation. These are summarized below:
Uneven Bolt Stress An incorrect boltup procedure or limited working space near one
side of a flange can leave some bolts loose while others crush the gasket. This is
especially troublesome in high-temperature services, when the heavily loaded bolts relax
during operation.
Improper Flange Alignment Improper flange alignment, especially nonparallel faces,

causes uneven gasket compression, local crushing, and subsequent leakage.
Improper Gasket Centering If a gasket is off-center compared to the flange faces, the
gasket will be unevenly compressed and more prone to leakage.
Dirty or Damaged Flange Faces Dirt, scale, scratches, protrusions, or weld spatter on
gasket seating surfaces provide leakage paths or can cause uneven gasket compression
that results in leakage.
Excessive Loads in the Piping System at Flange Locations Excessive piping system
forces and moments at flanges can distort them and cause leaks. Common causes of this
are inadequate flexibility, using excessive force to align flanges, and improper location
of supports or restraints.
Thermal Shock Rapid temperature fluctuations can cause flanges to deform

temporarily, resulting in leakage.
Improper Gasket Size or Material. Using the wrong gasket size or material can result
in leakage.
Improper Flange Facing A rougher flange-surface finish than specified for spiralwound gaskets can result in leakage.
Discussing the principal methods for correcting flange leakage problems is beyond the scope
of this course. However, several of them will be quite obvious based on the causes of leakage
highlighted above.
30
Piping & Valves

TYPICAL "CRISS-CROSS" BOLT-TIGHTENING SEQUENCE
FIGURE 6
31
Piping & Valves

Cleaning
Prefabricated pipe spools shall be visually inspected for cleanliness, have foreign matter
removed from the inside, and have end protectors installed.
After assembly and installation, the piping shall be cleaned inside to remove all material,
either by flushing or blowing with air as a minimum. Excess debris that is left in the line
could adversely impact process operations and cause equipment damage.
The interior of carbon steel piping for specific services such as boiler-feed water, lube
and seal oil, must be chemically cleaned since these services are especially sensitive to
even small quantities of dirt and corrosion products that remain in the pipe.
Pipe cleaning must be done so that soft seats of valves, control valves, and instruments
are not damaged. These components are typically removed from the system prior to
cleaning.
Buried Installation
Buried metallic plant piping shall have corrosion protection in accordance with the
applicable SAES-H and SAES-X standards. Buried installations shall be in accordance
with SAES-L-051.
The minimum cover in paved or otherwise stabilized areas shall be 450 mm (18 in.), or
as required by SAES-L-046. The minimum cover under paved roads shall be 760 mm
(30 in.).
32
Piping & Valves

Sample Problem 2
You have been assigned to review the installation of several new piping systems being
installed at Ras Tanura. As part of your effort, you have been watching flange installation
procedures being used by the contractor. The particular flange being installed is 600 mm (24
in.) in diameter and has 24, 38 mm (1-1/2 in.) diameter studs. The design pressure and
temperature of the system are 3,103 kPa (450 psig) and 427C (800F) respectively, and is in
a dangerous, hydrocarbon service. This is what you have observed:
The flange make-up crew inspected the flange surfaces and used a wire brush to clean
them.
Flange alignment was measured and compared to the required acceptance criteria. No
excessive force was used to bring the flanges into alignment.
They are having difficulty keeping the gasket in place since the flange is in a horizontal
pipe run. They solved this problem by using two strips of adhesive tape across the
gasket and attached to the flange.
The studs are inserted and the nuts finger tightened. Then three men take turns
tightening each stud by hammering on a stud wrench with a 5 kg (10 lb.) hammer as
hard as they can. Since the flange is fairly large and it is a very hot day, the men are
tightening the studs in sequence around the flange to avoid moving from one side of the
pipe to the other, and wasting time and energy.
Is this procedure acceptable?

Solution
This crew started out doing the job right, but did not finish the job correctly. The following
items are incorrect:
Tape installed in the manner described will likely lead to leakage during operation. If
tape is needed, it must be attached only to the edge of the gasket and not its face.
However, if the gasket is a spiral-wound-type, there should be a centering ring to keep
the gasket in place. If the gasket is a sheet-type, it should be cut so that its outside
diameter just contacts the bolts to help center it.
For the service described, it would be preferable if a torque wrench or stud tensioner
was used for boltup to help achieve more uniform bolt stress. If a hammer and wrench
is used, the highest force should not be immediately applied to each stud. It should be
applied in increments.
33
Piping & Valves

The studs should be tightened in a "criss-cross" bolting sequence.
34
Piping & Valves

Determining Whether Aboveground and Buried Piping Meet Installation

Requirements
The piping fabrication requirements that were discussed earlier apply primarily to all carbon
steel piping systems, but may be used for alloy piping as well, with some modifications. For
transportation piping, there are additional piping fabrication and installation requirements that
the engineer must be able to identify when auditing a contractor's work. These requirements
are located in SAES-L-051, which supplements ASME/ANSI B31.4 and B31.8. This section
discusses some of the requirements that are established in ASME/ANSI B31.4 and SAES-L051. This information should not be used to replace the standard for on-the-job applications.
Work Aid 3 summarizes these requirements.
Vertical Profile
A route drawing, detailed plan drawings, a piping and instrument diagram, a hydrostatic
test diagram, and other drawings required per SAES-L-020 shall be issued by the Prime
Engineering Office (PEO) and shall be the basis for installing the pipeline. The end of
the pipeline, Station 0 + 00, shall be stated in the Scope of Work, and is normally the
upstream end. A metric tape shall be used for the horizontal survey. Profile surveying
shall be in meters and decimal fractions of a meter.
The contractor shall determine the vertical profile of the pipeline, the amount of cover,
the location and degree of elastic and preformed bends, and the locations of vents and
drains in accordance with SAES-L-051 and the construction drawings. The change in
slope of the pipeline at normal spacing of 30 m (100 ft.), and at intermediate stations as
required, shall be calculated. The Saudi Aramco Construction Engineer shall approve
the contractor's design.
Saudi Aramco will typically do without predesigned vertical profile drawings, except at
locations where there are steep slopes, or above- to belowground transitions that require
special considerations. In all other cases, the required profile and required bends are
determined during construction.
The right-of-way shall be graded to a flat or smoothly rolling surface. Irregularities shall
not obstruct access of construction equipment. Fills and cuts shall be made to reduce the
number and/or magnitude of overbends and sagbends in the pipeline. Fill shall be
provided to support construction equipment in Sabkha areas as required. The width of
such fills and cuts shall not be less than the area to be stabilized, and the adjacent slopes
shall not be steeper than one in four.
If the pipeline construction will change the natural drainage pattern, either by the
grading of the right-of-way or by a bermed-over cover, provisions shall be made to
prevent washout of the pipeline cover by rain storms.
35
Piping & Valves

Elastic Bends
The maximum change in slope for elastic bends (bends that are made during installation that
do not cause pipe yielding), shall be in accordance with the Project Specification or the Scope
of Work. Larger changes of slope shall be made with preformed bends.
The pipeline design and stress analysis specifies the maximum permitted elastic-bend stress.
If this is exceeded, yielding might occur at points of maximum combined stress during either
the hydrotest or operations at higher temperatures. If the pipe must be yielded in order to
conform to the required profile, it should be done in a pipe bending machine during
construction to achieve adequate control and prevent possible ovaling, wrinkling or buckling.
Preformed Bends
Preformed bends are made by a pipe-bending machine which has mandrels and/or dies for
each pipe size. The machine causes a short length of the pipe to yield and conform to the
radius of the die. The result is a local "bite" in the pipe. The required preformed bend is
made by making a series of bites at regular spacings.
Preformed bends shall be made by welding into the correct location of the string a length
of pipe which has been bent with a smooth stretch-bending machine. No wrinkle bends
or hot bends shall be used. At any point along a preformed bend, the pipe diameter shall
not be reduced by more than 2-1/2% of the nominal pipe diameter.
Bends shall not be made closer than 600 mm (2 ft.) from a circumferential weld unless
the weld is backwelded. The weld shall be radiographed after the bend is made.
Making a bend closer to a nonbackwelded weld would introduce a high local stress at
the weld. Radiographing the weld after bending will identify any weld defects caused
by the bending.
36
Piping & Valves

Preformed Bends for Aboveground Pipelines

The maximum permissible localized bend or "bite" at one place on the pipe and the minimum
spacing of such bites are shown below:
Nominal Pipe Size

mm (in.)
150 (6)
200 (8)
250 (10)
300 (12)
350 (14)
400 (16)
450 (18)
500 (20)
600 (24)
750 (30)
900 and larger
(36 and larger)
Minimum Bite Spacing

mm (in.)
300 (12)
300 (12)
300 (12)
300 (12)
300 (12)
300 (12)
300 (12)
450 (18)
450 (18)
450 (18)
450 (18)
Vertical preformed bends shall be used when changes of slope are required which are
larger than permissible using elastic bends. The preformed bend shall be welded into
the string so that its center will be centered on the support at which the change in slope
occurs. Movements of the string due to temperature changes after the location has been
first established may be neglected. The maximum allowable angle of preformed bend
per support in a 900 to 1,200 m (3,000 to 4,000 ft.) string shall decrease as the distance
between the bend and either free end of the string increases, as shown below.
Distance From End of String,

m (Ft.)
0 to 60 (0 to 200)
60 to 120 (200 to 400)
120 to 180 (400 to 600)
180 to 275 (600 to 900)
Maximum Bend per

Bite, degrees
4.5
3.8
2.8
2.3
1.7
1.5
1.2
0.9
0.75
0.6
0.5
Degrees Per
Support
10
8
6
4
Change in Slope
0.1745
0.1396
0.1047
0.0698
For aboveground restrained pipelines, the support design shall limit the angle of vertical
bend per support to a maximum as indicated in the Project Drawings or Specifications.
A deflection anchor force acts at bends in restrained pipelines. The bend angle affects
the force that is transmitted to the support, and the support is designed for a maximum
permitted force.
37
Piping & Valves

For aboveground restrained pipelines, all horizontal deflections shall be made at

deflection anchors or consist of a series of very large radius field bends held in special
supports designed for horizontal thrust, as shown on the Project Drawings.
Preformed Bends for Buried Pipelines
Unless there are space limitations, the bends for buried pipelines shall be long radius
with maximum bend or "bite" at one place on the pipe of 0.50 and minimum spacing of
such bites of 0.9 m (3 ft.) In order to use a more severe angle for a preformed bend,
calculations, which consider expected temperature rise, weight of pipe, and fluid and
cover, shall show that such a bend will be adequately restrained.
Preformed horizontal bends shall normally consist of pipe joints with a maximum of 3
bend per joint corresponding to an overall bend radius of approximately 210 m (690 ft.)
for a 12 m (40 ft.) long joint. In order to use a smaller radius, calculations must show
that the bend will be adequately restrained.
Vents shall be installed at the major high points of the vertical profile when required by
the design per SAES-L-020. If temporary vents are used, nipples and valves shall be
removed and bosses shall be plugged and seal welded after the hydrostatic test.
Drains at the top of the line shall be installed at the major low points of the vertical
profile when required by the design per SAES-L-020.
Storage and Handling
Slings for lifting pipe shall be nylon or similar material. Wire rope slings shall not be
used without suitable protection. This is done to prevent high localized loads and
possible pipe deformation, or damage to an external coating.
Pipe shall not be rolled or dropped off trucks. The pipe handling procedure and
equipment shall be approved by the Construction Engineer.
Storage, handling, and installation of pipe that is externally coated with fusion-bonded
epoxy or polyethylene shall be in accordance with SAES-H-200.
Internally coated pipe shall be handled from the outside (OD) only. This is to prevent
damage to the internal coating caused by handling devices.
38
Piping & Valves

Installation of Aboveground Pipelines
Each length of pipe shall be examined to make sure it is free from internal obstructions.
Any obstructions shall be removed before the pipe is welded into a string. Pipelines
typically require the use of scraper devices, and internal obstructions could prevent their
free passage.
Pipe joints shall be welded in accordance with SAES-W-001 and SAES-W-012 to form
strings of 900 to 1,200 m (3,000 to 4,000 ft.). Pipe strings or portions thereof shall not
be moved until all welds therein have been fully completed.
When open ends of pipeline strings are not attended, they shall be capped to prevent
entry of foreign matter. Each string of the pipeline shall be cleaned to remove all debris.
Except for internally coated pipe, each string shall be gaged by passing an internal
gaging plate of not less than 90% of the inside diameter for pipe sizes smaller than 750
mm (30 in.), and 93% for pipe sizes larger than 750 mm (30 in.). Cleaning shall be done
before pipeline valves are installed, or the soft seats of valves shall be protected against
damage from debris.
Support spacing and type shall be in accordance with the plan and the profile drawings
in the Project Specification or the Scope of Work. Support elevations shall be
maintained within 6 mm (1/4 in.). If support elevations are established during
construction, the slope shall be calculated from the actual support elevations and
distances.
Ring girders shall be installed within 6 mm (1/4 in.) horizontal and vertical
tolerances.
Driven piles shall be coated to prevent corrosion and shall be driven in accordance with
the Project Specification.
Concrete supports shall use concrete in accordance with SAES-Q-001. The concrete
shall have a minimum compressive strength of 20.7 MPa (3,000 psi) after 28 days.
When supports are installed on fill, the fill shall be well compacted, shall be at least 1.8
m (6 ft.) in diameter, and shall be stabilized using marl or crude oil.
39
Piping & Valves

Installation of Buried Pipelines

The first three points previously noted for the installation of aboveground pipelines apply to
buried pipelines as well. The items that follow are in addition to these.
If the pipeline crosses other buried lines or comes within 30 m (100 ft.) of other buried
steel installations, a Cathodic Protection Engineer shall determine if bonding stations are
needed. All bonding stations shall be completed within seven days from the date the
pipeline is covered with backfill. The as-built drawings shall indicate the other buried
installations and any bonding stations. This is required to ensure that galvanic corrosion
of the pipeline does not occur.
Buried installations that cross the pipeline route shall be located in advance of grading
and digging ditches. The ditch bottom shall be surveyed to establish the elastic bends
and preformed bends that are required in rolling terrain or when passing through dunes.
When the pipe is lowered into the ditch, the pipe shall conform to the ditch bottom and
must be substantially supported at all points. The maximum allowable unsupported
length before backfilling is 3 m (10 ft.). Any larger voids shall be carefully backfilled.
The minimum clearance between pipelines or between a pipeline and an obstruction
shall be as specified in SAES-L-020, unless additional clearance is specified on the
pipeline drawings.
Spot backfilling shall be used to restrain the pipe in the ditch after it has been lowered
in. Spot backfill shall provide the full specified cover and shall cover all preformed
bends for a distance of 6 m (20 ft.) to each side of the centers of the bends. The
maximum clear distance between spot backfills shall be as specified by the project
design. Spot backfills shall cover the pipe for at least 4.5 m (15 ft.) along the pipe.
LPG lines, gas lines, and oilwell flowlines shall have a minimum cover of 900 mm
(3 ft.). Other lines shall have a minimum cover of 600 mm (2 ft.). The cover is
measured from the top of the pipe to the surface of the berm over the pipe centerline.
Original grade shall be restored to adequate cover over the pipeline unless otherwise
specified. Additional cover required at road or rail crossings shall be as noted on the
drawings.
The specified minimum cover depth applies to uncultivated areas and designated
pipeline corridors. The project design may specify a larger minimum cover in
developed areas and/or specific locations.
The project design shall specify where extra cover is required at vertical, horizontal, and
composite-preformed bends based on bend radius and tie-in temperature to adequately
restrain the buried pipeline. Such extra cover shall extend a minimum of 6 m (20 ft.)
beyond a bent portion of pipe.
SAES-L-051 also specifies requirements for installation in sand areas, rock areas, and Sabkha
areas.
40
Piping & Valves

Tie-in Temperature
The tie-in temperature must be measured because all thermal expansion or contraction takes
place from the installation temperature. The pipeline design assumed a specific tie-in
temperature range in making all stress and load calculations. Therefore, the piping
installation must be made to conform to the assumptions that were made.
A tie-in weld is each weld which connects a pipeline string to another string, to the
pipeline under construction, or to an anchor. The segment of the pipeline between tie-in
points remains fully restrained at the tie-in temperature if shrinkage of the segment is
prevented by adequate anchorage at both ends.
For normal diurnal temperature
variations during construction, one of the following will provide adequate anchorage:
-
Full-thrust anchor.
Intermediate anchor with a full string of pipe welded to each side of the anchor.
Friction forces along the "tail": at least 450 m (1,500 ft.) of buried pipeline, a 900
to 1,200 m (3,000 - 4,000 ft.) string on wooden skids or sand, or 1,800-2,400 m
(6,000 - 8,000 ft.) of pipe, a double string, resting on steel supports.
The Construction Engineer shall determine the highest practical tie-in temperature for
each tie-in weld of a buried pipeline, and for each aboveground pipeline segment from
one anchorage point to another. The tie-in temperature must be above the minimum or
within the range stated in the Project Specification.
The actual tie-in temperature shall be the average of two readings, one at the top and one
at the bottom of the pipe. The temperature measuring device shall contact the pipe and
shall be shielded from direct sunlight.
The Contractor shall record all tie-in temperatures and the pipeline stations of the tie-ins.
Specific methods of tie-in for buried pipelines, aboveground restrained pipelines, and
aboveground nonrestrained pipelines are specified in SAES-L-051.
41
Piping & Valves

Cleanup and Records

Specific instructions for cleanup and record keeping are in SAES-L-051.
Construction waste material shall be removed from the right-of-way as construction

progresses.
Records of tie-in temperature and all repairs shall be sent to the Prime Engineering
Office.
All survey data and as-built drawings shall be sent to the Prime Engineering Office.
This includes:
-
Bottom-of-line elevations and ground elevations at all 30 m (100 ft.) stations and at
all preformed bends.
The location and degree of all horizontal bends.
The location and degree of all preformed sagbends and overbends.
The location of all vents and drains.
The identification, station, elevation, and size of all pipes which cross the pipeline
and of any other buried steel within 30 m (100 ft.).
The stations of all markers and cathodic protection facilities.
All other data which should be included on a maintenance record profile, including
the stations of block values, anchors, road crossings, and changes in the grade of
the pipe, wall thickness and diameter.
Safety Instruction Sheets per SAES-A-005.
42
Piping & Valves

SPOOL PIECE DRAWING
FIGURE 7
43
Piping & Valves

SPOOL PIECE DRAWING
FIGURE 8
44
Piping & Valves

WORK AID 1: Procedure for Determining Whether Piping Meets Fabrication

Requirements
1.
Review purchase order to determine if any special requirements were specified.

Especially note any that are exceptions or additions to Saudi Aramco SAES or SAMSS
requirements.
2.
Confirm that Saudi Aramco Material System Specification 01-SAMSS-010, and

ASME/ANSI B31.3, B31.4 or B31.8 are referenced, as appropriate. This will establish
that the intent is to adhere to the requirements contained in these documents for items
not specifically identified on the drawings. These references may appear in the general
pipe fabrication and erection specification prepared for the project, rather than on each
fabrication drawing.
3.
Pipe Material Note: The following checklist items assume that there are no acceptable
deviations from 01-SAMSS-010, and that the material is carbon steel.
4.
5.
API 5L, Grade B through X60.
ASTM A53, Seamless Grade B, black.
ASTM A106, Grade B.
Nipples
Material same as pipe.
Schedule 80 minimum thickness.
Threading per ASME/ANSI B1.20.1 taper pipe thread.
Flanges
Weld-neck- or blind-type, unless otherwise specified in Purchase Order.
ASME/ANSI B16.5, ASTM A350, LF2 material, unless otherwise specified in

Purchase Order, based on SAES-L-009 or 02-SAMSS-011 requirements.
MSS-SP-44 if not specified by ASME/ANSI B16.5 or Standard Drawing.
45
Piping & Valves

6.
Pipe Fittings
Butt-welding fittings shall be used for nominal pipe sizes 50 mm (2 in.) and larger,
conforming to 02-SAMSS-005. Material grade and nominal wall thickness shall
be the same or equal to adjoining pipe. The following applies for carbon steel
pipe:
Pipe Material
7.
ASTM A234/A234M, Gr. WPB, plus

additional requirements of 02-SAMSS005
API 5L, Gr. X42 through X65
MSS SP75, plus additional requirements

of 02-SAMSS-005
Forged steel threaded or socket-welding fittings shall conform to ANSI B16.11,

pressure class 3000, and unions shall conform to MSS-SP-83. These may be used
for pipe sizes less than 50 mm (2 in.). ASTM A105 shall be used for carbon steel
piping systems.
Must be listed in the applicable code and have an SMYS of at least 207 MPa
(30,000 psi).
Mitered Joints
9.
A106, Gr. B; A53, Gr. B; or

API 5L, Gr. B
Steel Plate for Reinforcements and Structural Attachments
8.
Fitting Material
Maximum angular offset of 3 unless otherwise specified and approved.
Ends for Field Welding
Same alignment tolerance as above. Note if extra length added to permit cut back
for field adjustment.
Weld-end bevel 35 5.
1.5 mm (1/16 in.) root face.
End-plane normal to pipe axis within 0.25.
46
Piping & Valves

10. General Dimensional Tolerances
Maximum lateral translation of branch connections from centerline of run to be

1.5 mm ( 1/16 in.).
The tolerance for axial dimensions, face-to-face, center-to-face, and location of

attachments shall be 3 mm ( 1/8 in.).
Flange rotation measured as the offset between bolt-hole elevations on opposite

sides of a flange centerline shall not exceed 1.5 mm ( 1/16 in.).
Flange tilt measured at the periphery across any diameter shall not exceed
1 mm (1/32 in.) from the square position.
11. Piping Over 75 mm (3 in.) Size Connected to Machinery.

Flange alignment to be within following limits:
a.
Vertical bolt-hole offset:
0.5 mm ( 1/64 in.).
b.
Horizontal bolt-hole offset:
0.5 mm ( 1/64 in.).
c.
Rotational offset:
0.5 mm ( 1/64 in.).
d.
Flange-face tilt across diameter: 0.5 mm ( 1/64 in.).
e.
Flange-face
gasket thickness:
separation,
0.5 mm ( 1/64 in.).
47
Piping & Valves

12. Bends
Maximum dimension of flat spot, d:

d =
2 tD
= Nominal wall thickness
d = Nominal pipe diameter
Maximum difference between largest and smallest diameter to be 5% of nominal

pipe diameter at any point in the bend, and 3% of the nominal pipe diameter at the
ends.
Minimum thickness after bending not less than specified in purchase order.
Minimum centerline radius to be five times nominal diameter.
Bend no closer than the smaller of 1 1/2 times the nominal pipe diameter or
600 mm
(2 ft.) from circumferential weld.
Bend tolerances as follows, unless otherwise specified:
0.5 on bend angle
1% on bend radius
For pipeline:
-
Maximum localized bend at one place for aboveground, preformed bend per
SAES-L-051.
Maximum vertical angle per support for aboveground, preformed bend per
SAES-L-051.
For buried preformed bends:

-
Maximum localized bend at one place to be 0.5 at a minimum spacing of 0.9

m (3 ft.).
Maximum horizontal angle of 3 bend per pipe joint resulting in approximate

bend radius of 210 m (690 ft.) for a 12 m (40 ft.) long joint.
48
Piping & Valves

13. For Pipelines:
Support elevations: 6 mm(1/4 in.) from specified value.
Ring Girders: installed within 6 mm (1/4 in.) of horizontal and vertical positions
specified.
14. Weld-type vs. Usage
Butt-Weld Circumferential welds between pipe ends, between pipe ends and
butt-welded fittings or welded-neck flanges, plate edges formed to form pipe.
Fillet Weld Socket-welded connections, slip-on flanges, branch connection

reinforcing pads, and nonpressure containing attachments to pipe.
15. Welding Steps Review
General conformance to appropriate ASME/ANSI B31 and Saudi Aramco

requirements
Meet requirements of SAES-W-001, and SAES-W-011 or SAES-W-012, as

required
Welding procedure qualification
Welder and welding equipment qualification
Cleaning
End preparation
Preheat
Postweld heat treatment
49
Piping & Valves

WORK AID 2: Procedure for Determining Whether Metallic Plant Piping

Meets Installation Requirements
1.
Confirm that all pipe storage and handling requirements are being followed.
2.
Review specified pipe fitup requirements and installation tolerances, and confirm that
they meet ASME/ANSI B31.3 and SAES-L-050 requirements.
3.
Confirm that the more stringent installation tolerances for piping connected to loadsensitive equipment are being met.
4.
Review flange installation procedures and confirm that they meet accepted practices.
This includes the following:
a.
Inspect gasket seating surfaces and resurface as required.
b.
Clean gasket seating surfaces.
Align flanges to within required tolerances.
d.
Lubricate threads and nuts.
e.
Place gasket properly.
f.
Use proper boltup procedure.
Criss-cross bolt-tightening sequence
Gradually increase bolt load applied
Use torque wrench or stud tensioner for critical, high-temperature, or highpressure services.
5.
Confirm that pipe spool pieces and assemblies have been properly cleaned.
6.
Buried installations to meet corrosion protection and cover requirements specified in

SAES-L-050.
50
Piping & Valves

WORK AID 3:Procedure for Determining Whether Aboveground and Buried

Pipelines Meet Installation Requirements
1.
Confirm that all required drawings have been issued, and that they meet project
requirements.
2.
Right-of-way to be graded to a flat or smoothly rolling surface.
3.
Check width and slope of fills and cuts.
4.
Confirm that the resulting drainage patterns are acceptable.
5.
Check that specification and location of elastic and preformed bends are in accordance
with SAES-L-051.
6.
Confirm that pipe storage and handling provisions are acceptable.
7.
Confirm that installation details of aboveground and buried pipelines meet requirements
of SAES-L-051.
8.
Measure and record tie-in temperature. Confirm that it meets project requirements.
51
Piping & Valves

GLOSSARY
arc cutting
Use of an electric arc generated at the tip of a welding electrode to

cut metal.
backing ring
A relatively narrow, circular section placed in back of a buttwelded joint prior to making the root pass of the weld. This is done
to achieve a
full-penetration weld when the back side of the weld joint cannot
be accessed.
bolt tensioner
A mechanical device used to tighten bolts by applying a uniform,

calibrated load. It attaches to the end of the bolt, stretches it by
applying a load, and then permits easy turning down of the nut to
hold the load in the bolt.
pipe joint
This word has two meanings depending on the context.

(a) The interface between two components, such as at a weld,
flange, or
threads.
(b) In pipeline applications, a single section of straight pipe before
being
welded into a longer section.
radiography
The use of radiant energy in the form of neutrons, x-rays or gamma

rays for the nondestructive examination of opaque objects. It
produces graphical records on sensitized films which indicate the
comparative soundness of the object being tested.
root pass
The first weld bead made.
slag
A nonmetallic blanket that forms on the top of the molten weld

metal.
It helps to control the temperature, the cooling rate, and assists in
preventing and removing impurities from the weld metal.
union
A pipe connector that is made of two mating pieces, one for each
end of the two pipes being joined. The two halves of the union are
held together by a threaded ring.
water quenching
Rapid reduction of metal temperature after a hot forming process

by using water.
52
Piping & Valves

weld
A localized union of metal achieved in plastic and molten states,

with or without the addition of filler metal or application of
pressure.
wrinkle
A deviation of the pipewall from the ideal contour of more than

15% of the nominal wall thickness perpendicular to the surface.
53

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