Saudi Aramco Inspection Checklist

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2012)
Rev 6
SAIC NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST

Review & Approve Piping Fabrication Shop
(Guide - Assure Successful Project Start-up)
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
31-Mar-12
DATE APPROVED
DISCIPLINE
30-Apr-13
CONTRACTOR/SUBCONTRACTOR
EQUIPMENT ID NUMBER
EQUIPMENT DESCRIPTION
EQPT CODE
SYSTEM
LAYOUT DRAWING NUMBER
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
Note
1-5
A1
A2
A3
A4
A5
A6
A7
REQUESTED INSPECTION DATE
ACCEPTANCE CRITERIA
REFERENCE
1. Contractor informs Company when a Subcontractor (or his own)

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

Special Process Procedures were submitted 30 days prior to the start of
any work (operations) at fab shop as follows:
No
N/A
Comments
Use this guide

on interviewing
Project Quality
QA/QC Mgrs for
Prime
Contractor &
Subcontractor
for quality start
on major
projects
STAGE 1
Sch. Q, Att. V,
Special Process Procedure Revision Approval is received BEFORE

Sch. Q, Att. V,
starting production work (operations) at new shop.
Welding Engineer (Contractor) is available for WPS package
review/approval before "30 days Prior" submission deadline
SA Approved Engineer is at site (6-8 weeks before
SCH. Q, Att. VI,
shop kick-off)
Table 2
Engineer can expedite WPS revisions that
avoid work
start delay.
Welding
Procedures
Package (WPS) per SAES-W-011 Sect 7. A) Piping
WPS packages were submitted 30 days before work.
CSD has returned Status 1 or Status 2 cover sheets for all WPS
Complete list
of WPS is available in timely manner (no work delays)
Sch. Q, Att. V, &
B) Structural procedure package to Project Inspection early
IV
Use AWS
D1.1 Prequalified welding procedures
Maintain list of procedures/status at site
Welding Special Process Procedures & Controls are revised & approved
(Sch. Q, Att. V, BEFORE work starts):
A) Gap
Control for socket welds (meets code as revised)
B) Seal
welding threads (Meets SAES-L-110 & code as revised)
C) Weld Consummable Control (Store, Issue,
Reuse, Monitor)
D) Welder
Tracking (Qualification, WPS monitoring, retraining, etc)
Sch. Q, Att. V, &
E) Heat input measurement & WPS monitoring
IV
(pipe welding)
F) Pipe weld
repair (weld defect repair, buttering, base metals)
G) Pipe welding related (Bevelling, joint & surface
prep, preheat)
H) Repad
Installation, Bending & Forming (pipe bends, ovality)
i) Structural Welding related (splicing, weld
repair, prep, etc)
Welding Procedure Qualifications (for new shops):
A) Procedure Qualification Records (PQRs) are
prepared/submitted on SA Forms (Attachment A).
B) Weld and Line Designation Table
("Weld Table") is submitted along with PQR documents (Attachment B) &
provides a listing of materials, thickness, & weld joint types (individual
SCH. Q, Att. IV,
line designation).
C) Hardness Testing is per SASD AB036386 (mandatory)
D) Ferrite measurements per AWS
A4.2 (as applicable).
E) Weld maps & tables
are detailed & attached
F)
Originals of all test records, mill certs, etc., are available to SA.
Never assume CSD previously approved WPS are valid. Check Weld &
Line Description Table details:
A) Verify that service considerations are identical
B) ORIGINAL CSD Cover Sheet listing status/restrictions is
available
C) Groove Weld procedures do not cover socket
welds & fillets
Additional sketch or clear field
instruction notes for QC & welders is needed for socket & fillet welds
(size, # passes,etc)
Yes
SAES-W-011,
Section 7
Page 1 of 21
CSD has the

six-week policy
on WPS returns
As Applicable
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
A8
WPS Drawing Details (CSD common revisions):

A) Branch Connection Drawings are detailed to show
applications
B) Weld size & prep depth shown
(Drawings/Notes). Round up mm.
C) Single V-Groove
Drawings reflect the following Notes:
Maximum value for t
Maximum weld metal deposit value (GTAW, SMAW, etc)
D) Fillet Weld Notes provide clear instruction to
Sch. Q, Att. IV
welders & QC:
Minimum size (full fillet) or a min for seal welds/shims
Detail/note integral acute angle attachments (dummy leg, bracing)
E) Socket Weld Notes provide clear instruction to welders & QC:
Minimum number of passes (2), fillet size, shape, contour
F) Seal Weld Notes provide clear instruction to
welders & QC:
Process, sequence, shape, "no exposed threads" & NDT (MT/PT)
Ensure documents are not returned unapproved by CSD
A9
WPS Miscellaneous details (CSD common revisions):

A) SMAW & GTAW diameter limits
per SAES-W-011 are correct
B) Back purge rate
notes (O2 level below 1% verified by analyzer)
C) Galvanize welding
(sch. 80+) has special prep & test procedure.
D) Heat input limit
range calcs are closely checked & correct
E) ER70S6 is not utilized (GTAW). Use ER-70S-2, 3 (NACE matl's).
Sch. Q, Att IV
F) E-7018-1 (increased manganese) is specified for SMAW welds
when Low Temperature applications are required at the Fab Shop.
G) PQR Hardness Values do
not exceed 200 BHN (NACE WPS)
H) Travel speed RANGES
are specified. Maximum Oscillations (3 x wire diameter) are verified to be
within correct range (travel speed)
i) Preheat Tables provide
clear field instruction (SAES-W-011, etc)
A10
Check WPS Weld & Line Description Table for misc. details:
A) Identify lines that require Charpy
Impact, PHWT & BHT (values)
B) Cement lined
pipe welding requires special CSD considerations
C) Base
metal thickness range requires backing (butts below 1/8")
D) 100% PT & RT for GTAW butt welds below 1/8 or 3.2mm
E) A separate procedure requiring surface
preparation details and coating repair must be submitted for welding
galvanized piping.
F) Piping class
12LE0U1 (FBE-lined piping) requires similar treatment
A11
NDT/NDE Technique procedures have been Dhahran approved

Cover letter approval from NDTU Dhahran has been
received
Revision requests and changes
from NDTU Dhahran are complete
A12
A13
A14
Equipment & Set-up (See SAES-H-100 Checklists A,

B, C, D)
Location (Site) & Operations must be
approved by Saudi Aramco
Coating
crews (blaster, painter, & supervisor) have SA cards.
Heat Treatment Procedure & Equipment Package is CSD approved
(similar to Welding per SAES-W-011, Section 13):
Cover letter approval from CSD has been received
Revision request/changes from CSD have been
A15
No
N/A
Comments
SAES-W-011,
Section 7
Sch. Q, Att.IV,
NDT/NDE CONTROL procedures are issued and clear for all

NDT controls by prime contractor assure adequate
supervison
Critical elements in
Control procedure maintain NDT integrity
Guide
Sch. Q, Att. IV,
for PID Review (NDT CONTROLS)
Know the difference
between NDT "Technique" Procedure & and NDT "Control" Procedure.
Control is mandated by Q.
PMI procedures & Equipment (Package) is CSD approved
Equipment for testing is at site or readily available
Material
receiving checks & system of testing identification known
Coating Package (application/procedures) has been approved
Yes
Sch. Q, Att. IV,
Sch. Q, Att. IV,
Sch. Q, Att. IV,
addressed
CSD has returned Status 1 or Status 2
cover sheets for WPS
Page 2 of 21
Attachment 1
Guide for
approval of NDT
control
Procedures
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
Heat Treatment (associated process) requirements:

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

Contractor has certificates available for hardness testing
bars.
B
Welder Qualification Testing

(Welding Equipment Set-up & Welding Consummables)
B1
Prior to welder qualifications, Shop Controls are established for welder

WPS monitoring (heat input measurement & hardness tests),
consumables, documentation & test materials.
B2
B4
N/A
Comments
STAGE 2
Welder Testing (Procedures & Controls) are approved:

A) An independent 3rd party (SA approved)
has been selected
B) Company is notified prior to any
testing.
C) Test
Facilities are available at the Shop (to be approved).
D) Equipment meets SA standard requirements (CS, alloy & SS)
Sch. Q, Att. IV,
SAES-W-011,
Section 7
Machine spacing & clearances (layout) is adequate and safe.

Routing of cables & controls does not present safety
Contract Based
hazards.
Ventillation & air supply is adequate
Safety
for testing/training.
Requirement
Grounding tests (equipment is well grounded) are performed
Schedule A, B,
Electrical system & controls have been tested & are
et al
properly rated
Training/Testing
areas have proper test stands and work support
Covers (to prevent arc flash) are in
place for personnel protection
Welders are considered competent, qualified through practice & trained
in WPS & SA requirements by QC in place before testing by approved
3rd Party. (Identify experienced welders with JCC cards)
SAES-W-011,
Section 7.2.5 a
Welding Procedure Controls for Low Temp Applications:

Initial welding (first ten, etc) is monitored
(calibrated tong testers).
Best welders selected (Consistently meet Heat Input & Hardness)

B5
No
SAES-W-011,
Section 13 & 14
Welder Testing Facility is first approved (Safety, Electrical):
B3
Yes
Sch. Q, Att. IV
Contractor use of E7018-1 (SMAW fill & cap) is strictly
assured.
PMI can distinguish higher
manganese content in E-7018-1
Welders with
marginal heat input results are reassigned.
B6
Welding on NACE material is performed as follows:

A) Welders are NACE experienced & familiar with NACE WPS
B) Welders meet NACE WPS
NACE Standard
Heat Input & hardness values.
MR0175
C) NACE welders are listed on a roster & on SA JCCs.
D) CS Welders demonstrate NACE ability through
Section 5.3
daily monitoring.
E) Shops start early monitoring of Heat
Input during training & testing to qualify any welders for NACE welding &
Low Temp applications.
B7
Work stations for each welder are checked as follows:

A) There are a sufficient number of uncrowded work stations.
B) Stations are level & capably support
fabricated components.
C) Sufficient
shielding protection exists for welder work stations.
ANSI Z49.1,
Annex J
B8
Welder training & testing areas are segregated or in a separate area

where approved welders with JCCs perform shop work.
SAEP-323,
Section 6
B9
Welding machines for each work station have current calibration
B10
Welding power supplies were calibrated per British Standard 7570 when
impact toughness tests are required (SA, spec or code)
Sch. Q,
Section 3
SAES-W-011,
Section 19
Page 3 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
B11
Welding machines (singular or banked) have sufficient spacing and

ventilation to dissipate heat.
ANSI Z49.1,
Annex J
B12
Welding machine leads are in good condition & are fed to each work
location as follows:
A) Organized & safely secured (tie wraps) overhead routing exist
B) Laid out & properly
covered in walkways for access/egress
C) Method of lay out is an orderly fashion that prevents tripping.
D) Lead routing through heavy equipment (forklift,
crane, etc) area is between 2x4's or under inverted channels to prevent
damage.
ANSI Z49.1,
Annex J
B13
Gas cylinders at welder stations are properly secured with quality hoses
and fittings rated for use in GTAW set-ups (rigs).
ANSI Z49.1,
Annex J
B14
Each welder is supplied with the following at his work station.

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

ANSI Z49.1,
Annex J
B15
Welding Facilities (Environmental Shielding) provides adequate

protection from elements of wind, sand & rain:
A) Condition of the roof is good (no holes, missing panels, etc)
B) Doors for closure are available
and function properly
C) Partitions
are installed & properly oriented for environment.
D)
Wind Shields or tents are available in adequate numbers
SAES-W-011,
Section 11.2
B16
Welding equipment set-up & testing is complete:

A)
Maintenance, testing & monitoring records are available.
B) Machines have a unique ID number
C) Machines have leads and
connections secured (as calibrated). D) Machines are properly grounded
(tested & passed per results)
E) Current Calibration sticker (checked with calibrated tong tester)
F) Machine
Controls function properly & current values are legible
G) Special GTAW equipment is available (Corrosion-Resistant Mat'l) H)
Electrical supply & outlets are adequate & safely installed.
Sch. Q, Att. IV,

Section 4
B17
Welding Electrode & Consummable Storage:

A) Climate controlled storage area is clean & free of dust & moisture
B) Area is secured and has counters to control access
C) Consummable Control
personnel (issue) are available & trained
SAES-W-011,
Attachment 1 & 2
B18
Drying, Storage & Portable ovens are operable with calibrated controls
(temperature gauge) per SAES-W-001 Table 1 Ranges. SAES-W-011,
Table 1 requirements are posted near ovens.
SAES-W-011,
Attachment 1 & 2
B19
Calibrated weld rod holding ovens are set up & controlled:

Initial baking
Re-conditioning
Weld rod oven interior map indicates weld rod type & location
Weld rod oven interior map indicates weld rod
status (final issue).
Logs, issue slips, rod receipt
records, bake records, etc, exist.
SAES-W-011,
Attachment 1 & 2
B20
Pressurized gas cylinder (consumable) storage:

A) Designated area exists for storage of cylinders
B) Segregation (marking & identification) exists in
storage area.
C) Warning signage exists for this
area (No smoking, cautions, etc)
D) Storage area is on level
concrete surface with bottles upright.
E) Storage
area can be locked & secured to prevent access.
F)
Locks & chains are available for cylinder storage areas.
G) Tags (certs) are attached to cylinders (from approved
sources)
H) Records of receipt & documentation (log)
kept on all cylinders
AWS Z49.1,
Annex J
Page 4 of 21
Yes
No
N/A
Comments
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
B21
Shop has welding equipment (& tool) maintenance & repair ability.
Alternately, Maintenance company performs repairs.
AWS Z49.1,
Annex J
B22
Shop has a Tungsten grinder (diamond cutting/grinding/shaping) &

follows quality GTAW equipment & consumable handling practices.
Procedures cover specific practice ... See Also SAIC-W-2006
AWS C5.5,
Section 6
Yes
No
N/A
Comments
Manpower Reqmts (Quantity & Qualifications) Note: Task all inspectors with reqd reading (SATIPs). Tests after required
reading are given by discipline with a goal for Process Improvement (SA System Training/Orientation)
C1
Construction Manpower Forecast (start-up & peak) showing total

numbers (welders, fitters, helpers, etc) is available.
Schedule Q,
Sec- VI Table 2
C2
QC MANPOWER FORECAST (start-up & peak) showing total number of

inspectors, engineers & supervisors is available.
Schedule Q,
Sec- VI Table 2
QC Manpower meets Construction manpower ratios.
Schedule Q,
Sec- VI Table 2
C4
CV-approved Quality personnel arrive early* (10-days before work) for

job training & any testing requested by Saudi Aramco.
Schedule Q,
Sec- VI Table 2
C5
Quality Personnel experience minimum requirements (Contractors or

subcontractors that perform the work) per Sch. Q:
A) Have 10 years of industrial experience minimum (Age 27)
B) Have 6 years experience in a given
inspection specialty
C) Have 4 years
(of 6 years) in Oil & Gas (petrochemical) industry
D) High School graduate, or equivalent
E) Fully conversant with
applicable Industry Standards & Specs
F) Can perform inspection functions with minimal supervision.
G) Can pass a SA interview
& testing when requested by Company
SCH. Q, Att. I,
Qualification
Requirements
C6
Welding/Mechanical Inspectors:
A) Certified as a CWI, CSWIP Certified Welding
Inspector.
B)
Knows codes (ASME B31.3, 31.4 & 31.8, ASME V and IX, API 620 & 650,
AWS D1.1, required for the execution of the WORK.
C) Can monitor NDT work & results
D) Qualified ASNT Level II (relevant methods) when
performing, viewing, ensuring or auditing NDT specific method(s).
E) Pass interview & test given to welding QC
(knows workmanship, code undercut, WPS, socket weld specific reqmts
& references, understands service implications and RELATED
SPECIFICATIONS)
SCH. Q, Att- I
HAVE ALL
WELDING QC
TAKE TEST
C7
Heat Treatment Inspector:

A) Five years work experience (heat treatment tech or
supervisor) B) Knows heat treatment methods/equipment used on
projects
C) Knows requirements of
ASME B31.3 code & passes SA test
SCH. Q, Att- I
HAVE ALL
PWHT QC
TAKE TEST
C8
Coating Inspector: Inspector demonstrates a thorough working

knowledge & proven ability in critical coating applications/methods &
recognized industry standards. Inspector is qualified to NACE Level II
Critical Coatings Certification, CSWIP Level I, or equivalent.
INSPECTOR DEMONSTRATES ORGANIZATION & PROFICIENCY IN
SAES-H-100 ATTACHMENTS A, B, C, D for SA INSPECTION
SCH. Q, Att- I
HAVE ALL
COATING QC
TAKE TEST
C9
All IK CONTRACTOR & subcontractor NDT personnel performing NDT

operations, or interpreting, reviewing, ensuring or auditing NDT
operations meet SA requirements of SAEP-1142 & hold current NDT
certifications. Also, RTFI Personnel must be certified by SA.
NDT Personnel are monitored at start of work (Issue RFI).
SCH. Q, Att- I
NDT TECHS
Demonstrate
Competency in
the field
MONITOR initial
work closely
SCH. Q, Att- I
Dedicated solely
for QA Mgr
duties & Quality
Concerns
C3
Quality Assurance Manager is approved:

A) Has demonstrated knowledge & training (ISO9000 int'l stds)
B) Has a university
degree or equivalent
C) Has a minimum of 10 years of direct experience in QA system
activities in the oil, gas and petrochemical industries.
D) Is willing to address Quality & Continuing Process
C10
Improvements as required by approved Quality Plan to SA customer
satisfaction
E) Understands the entire workscope for
which he is responsible
F) Passes day-long
interview & test (as needed) for new QA Mgr. Note: Interview of Prime QA
Mgr & Subcontractor QC Managers together recommended to see how
they interact as a team and respond to SA expectations. Utilize this
checklist on interview/test.
Page 5 of 21
STAGE 2
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
C11
Quality Control Manager is approved:

A) Has demonstrated knowledge & training in the use
of measuring and test equipment routinely used in conducting
inspections.
B) Has university degree &
7 years inspection experience OR
C) Has HS diploma with 10 years inspection experience
related to supervision of construction activities (Oil, gas & petrochemical)
SCH. Q, Att- I
Other Duties do
not conflict with
QC Mgr duties
SCH. Q, Att VI,
HAVE ALL PMI

TECHS
TESTED
SCH. Q, Att- I
HAVE ALL
CRANE
INSPECTORS
TASKED TO
READ
PMI technician & PMI procedures are available.

A) PMI technician is qualified & certified as an ASNT
RT Level I
B) Has at least one year
experience in using PMI instruments.
C) Has passed a SA demonstration test with an approved PMI
C12
instrument on an alloy sample with 100% correct assessment.
D) PMI Technician works to an approved written procedure.
E) PMI technician has documented training (instrument &
procedure)
Approved by COMPANY (demonstration test performance)
Crane Inspector (demonstrates thorough working knowledge of
codes such as ANSI-A17.1 & 17.2, ANSI-B30.1 through B30.16) for
certification of cranes in newly constructed shops as follows:
A)
C13 Concrete structural foundation inspections are performed
B) Calculations for foundation & anchoring are
available to SA
C) Certs documenting Crane
capacity & construction are required
Crane
Inspectors are available for work & tasked to read
C14
Adequate supervision is available for the quantity of shop workers for all
shifts.
No
N/A
Comments
Schedule Q,
Sec- VI Table 2
Schedule Q,
Sec- VI Table 2
C15 Adequate QC works Full Time while work is in progress.
C16
Yes
No Conflicts of Interest exist regarding personnel, NDT Companies, Third

Schedule A,
Party Inspection agency personnel & Contracted Inspection personnel
Section 20
performing the work.
& Sch. Q
Personnel from other projects have approval/release letter.
Shop Layout & Location of Facilities
STAGE 2
D1
Shop/Yard Layout Map is available during walkdown & review.
PFI-ES-43,
Section 1
Environmental
controls
D2
Shop/Yard Layout is based on quality engineering controls & considers

prevailing winds, dust movement & contamination.
PFI-ES-43,
Section 1
Environmental
controls
D3
Segregated & enclosed area installations are complete.
PFI-ES-43,
Section 1
Environmental
controls
D4
Valve Testing Facility is upwind of CS dust & contaminants, enclosed &

shielded from the elements (fouling & contamination).
PFI-ES-43,
Section 1
Environmental
controls
SS & alloy work areas are located upwind of all CS work areas.
PFI-ES-43,
Section 3.6
Environmental
controls
Coating operation is downwind or isolated, enclosed & shielded.
PFI-ES-43,
Section 3.6
Environmental
controls
SAES-W-011,
Section 13
Environmental
controls
SAEP-1141,
Section 1
Environmental
controls
D5
D6
D7
PWHT facility or area is segregated, barricaded, accessible, well

ventillated, with adequate supports & weather protection for work.
D8
Radiography set-up per SAEP-1141 (Industrial Radiation Safety):

A) Shop is prepared for NDT Unit Dhahran SAEP-1141
Safety Audit
B) Copy of Radiation Safety
Manual (SAEP-1141) is available
C)
Radiography location is isolated (2mr boundaries, barricades).
D) Equipment storage areas are approved, locked
and secured
E) Transportation &
Handling Safety measures are known
D9
Storage yard is of adequate size to accommodate the types of materials

expected to be received during the course of the project.
Sch. Q, Att. IV,
D10
Storage yard organization allows easy material access & flow (for proper
movement & handling) during the course of the project.
Sch. Q, Att. IV,
D11
Preservation & Special Storage requirements are known and adequate

space exists with carefully planned material organization.
Sch. Q, Att. IV,
D12
Quarantine Areas are established (includes a tagging system) for reject

materials. Fence or other marked boundary is in place.
Sch. Q, Att. IV,
Page 6 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
D13
E
ACCEPTANCE CRITERIA
REFERENCE
OFFICE SPACE clearly designated for Company & Contractor is

available. Facilities for SA work access are per the contract.
Electrical Inspection & Safety (Access/Egress & Equipment)
Contract Safety
Requirement
E2
Shop has sufficient electrical outlets (support for workstations).
Contract Safety
Requirement
E3
Electrical outlets & extension cords have GFIs & dust covers.
Contract Safety
Requirement
E4
Electrical power feeds (j-boxes, power, lighting, etc) are installed.
Contract Safety
Requirement
E5
Terminals for weld leads & power cables are shielded from contact by
personnel or by metal objects (vehicles, cranes, etc).
ANSI Z49.1,
Annex J
E6
Welding Connections between welding leads & power supples are

guarded by one of the following methods:
A) Dead front construction and receptacles for plug
connections
B) Terminals located in a cover
C) Insulating sleeves
D) Other
equivalent mechanical means.
ANSI Z49.1,
Annex J
Welding Grounds are inspected/tested & in good condition.
ANSI Z49.1,
Annex J
The workpiece being welded & the frame or chassis of all electrically
powered machines is connected to a good ground.
ANSI Z49.1,
Annex J
E9
Grounding is done by locating the workpiece or machine on a grounded

metal floor or platen, or by connecting it to a properly grounded building
frame or other satisfactory ground.
ANSI Z49.1,
Annex J
E10
Chains, wire ropes, cranes, hoists, etc are not be used as grounding
connectors or to carry welding current.
ANSI Z49.1,
Annex J
E11
The workpiece lead is not the grounding lead. The workpiece lead
connects the work terminal on the power source to the workpiece.
ANSI Z49.1,
Annex J
E12
A separate lead is required to ground the workpiece or power source

work terminal.
ANSI Z49.1,
Annex J
E13
The welding current magnitude is safely carried by the grounding

conductor (not overloaded, hot).
ANSI Z49.1,
Annex J
E14
Areas are clear of tripping hazards. Lay out of production areas

for gas hoses, cables, mechanical assemblies, and other equipment do
not cross walkways or interfere with routine tasks.
AWS Z49.1,
Annex J
E15
Work above ground or floor level has safety rails or lines to prevent falls.
Safety lines & harnesses are available for fall protection.
AWS Z49.1,
Annex J
E16
Fire and explosion escape routes are identified and kept clear so that
orderly, rapid, and safe evacuation of an area can take place.
AWS Z49.1,
Annex J
E17
Equipment, machines, cables, hoses & other apparatus are placed to

prevent hazards to personnel in passageways. (ladders, stairs).
AWS Z49.1,
Annex J
E18
Warning signs are posted to designate welding areas & they specify that
eye protection must be worn.
AWS Z49.1,
Annex J
E19
E20
N/A
Comments
Identify Hazards
Shop has adequate lighting (fixed overhead & portable lights).
E8
No
Sch. Q, Att. IV,
E1
E7
Yes
Protective screens exist for persons in areas adjacen to welding & cutting
operations to protect them from radiant energy & hot spatter:
A) Flame-resistant screens or shields
B) Suitable eye and face protection and protective
clothing.
C) Appropriate radiation protective
semi-transparent materials
Combustible control in welding areas is handled as follows:
A) Combustibles are stored away or
shielded from welding/cutting.
B)
Combustible floors, roofs, partitions are not found in weld areas.
C) Building contents
including trash, wood, paper, textiles, plastics and chemicals are kept
away from welding areas
D)
Flammable gases and liquids are kept away from welding areas.
E) Outdoors, dry grass & brush are kept away from
welding areas.
AWS Z49.1,
Annex J
AWS Z49.1,
Annex J
Page 7 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
E21
Excessive noise, particularly continuous noise at high levels that can

damage hearing is identified & warning signs/zones exist.
AWS Z49.1,
Annex J
E22
Machinery Guards are available to protect welders & other workers from
injury by machinery & equipment being operated.
A) Moving components & drive belts are covered by guards to
prevent physical contact. (especially grinders)
B) Workers are protected against
accidental entry into the working envelope of all machinery and robotic
equipment.
C) Because welding
helmets and dark filter lenses restrict visibility of welders, special
attention is required for these hazards.
AWS Z49.1,
Annex J
E23
Persons do not consume food in work areas where toxic fumes are
generated to avoid ingestion of contaminants. Lunch areas are
designated and wash stations are readily available.
AWS Z49.1,
Annex J
E24
E25
Equipment is installed in clean, dry areas and adequately protected from

dirt and moisture.
EQUIPMENT for use is adequate for the scope of work required.
A) Structural support fabrication areas & equipment
are adequate
B) Structural steel (jigs and cutting
machines) are in good condition.
C) Pipe
rolling method exists for thick segments
D)
Air Compressors are adequate for supply at peak of work.
AWS Z49.1,
Annex J
AWS Z49.1,
Annex J
E26
Shop floors are level, clean and stable for ongoing work.
Contract Safety
Requirement
E27
Shop has adequate ventilation and air movers.
Contract Safety
Requirement
E28
Fire Extinguishers are stationed throughout the work areas
Contract Safety
Requirement
E29
Overhead cranes (existing shops) for lifting have current certification, are
properly rated, & are found in good condition.
Contract Safety
Requirement
E30
CRANE CERTIFICATION for smaller cranes in newly constructed shops

must be documented as follows prior to shop approval:
A)
Concrete structural foundation inspections are performed
B) Calculations for foundation & anchoring are
available to SA
C) Certs documenting Crane
capacity & construction are required
Contract Safety
Requirement
E31
Portable hoist & fork-lifts are rated & in good working condition.
Contract Safety
Requirement
E32
Access & egress pathways for fork-lifts & hoists are sufficient.
Contract Safety
Requirement
E33
Sufficient passage ways exist for personnel exit in an emergency
Contract Safety
Requirement
E34
Lifting components (slings, shackles, wire ropes, etc) are good.
Contract Safety
Requirement
E35
Overhead crane installations have been inspected & load tested.
Contract Safety
Requirement
E36
Storage racks & shelves are level & sufficiently supported
Contract Safety
Requirement
E37
Safety Lanes (for access/egress) are marked in saftey colors such as

yellow & black, etc to identify hazards
Contract Safety
Requirement
E38
Safety Signage & Markings identify hazards (posts, doorways, etc)
Contract Safety
Requirement
E39
Disposal bins (trash cans, metal refuse, plastics, etc) are marked to
identify contents allowed inside them (fire hazard warnings).
Contract Safety
Requirement
E40
Overall housekeeping of the shop is sufficient to prevent a fire.
Contract Safety
Requirement
E41
E42
Paints, coatings & NDT supplies are stored per manufacturer's

recommendations in climate controlled areas out of direct sun.
Cleaning materials & chemical storage as follows:
A) Flammable material storage is away from heat/electrical sources
Storage is per manufacturer's (warning label) data sheet
(MSDS)
B) Cloths & Rags are stored & issued
by Consummable Control
Cloth & rag storage bins have covers that are kept closed.
Used (refuse) Cloth & rag disposal bins are available.
Contract Based
Requirement
Contract Based
Requirement
Page 8 of 21
Yes
No
N/A
Comments
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
E43
Supervisors & workers know protocol in case of emergency
Contract Safety
Requirement
E44
Emergency services (ambulance) is available.
Contract Safety
Requirement
E45
Precautionary labels on consumables & equipment concerning the safe

use of the products are available for reading & guidance.
Contract Safety
Requirement
Austenitic Stainless Steel & Nickel Alloy Shops
PID Guide
F1
Stainless Steel & Nickel Alloy Shops address material Handling &
Storage, Fabrication & Shipping per Piping Fabrication Institute (PFI)
Standard ES-43.
PFI-ES-43,
Section 1
F2
Stainless Steel & Nickel Alloy Shops are safely & properly ventillated
(ANSI Z49.1). Adequate air movers lift toxic fumes.
PFI-ES-43,
Section 1
F3
Handle Austenitic stainless steel & nickel alloys with nylon slings or
equipment protected with a non-contaminating buffer mat'l.
PFI-ES-43,
Section 2.1
F4
Receive these alloys and conduct a visual exam of both internal &
external surfaces to detect existing contamination or gouges caused by
contact with contaminating material.
PFI-ES-43,
Section 2.2
F5
Fittings are stored on pallets or shelving that is constructed of noncontaminating material.
PFI-ES-43,
Section 2.3
F6
Storage areas for these materials are separate from the areas where
carbon steel material is stored.
PFI-ES-43,
Section 2.4
F7
SS material stored outdoors is covered with water repellent sheet.
PFI-ES-43,
Section 2.5
F8
Carbon steel strapping is used if a durable, non-contaminating material

(clean wood, cardboard, cloth, paper & SS buffer) isolates the strapping
from contact with the stainless steel or nickel alloy.
Gray duct tape (high chlorides) is absolutely prohibited
PFI-ES-43,
Section 2.6
F9
Walking on austenitic SS or nickel alloy material is not allowed.
PFI-ES-43,
Section 2.7
F10
Fabrication requirements (austenitic stainless steel or nickel alloy): A)

Contact surfaces of tools & equipment containing CS, zinc, copper or
their alloys are covered in a noncontaminating material.
PFI-ES-43,
Section 3.1
F11
Tools such as grinding wheels & wire brushes previously used on carbon
steel are not used on stainless steel or nickel alloys.
PFI-ES-43,
Section 3.2
F12
Grinding discs, abrasive discs & belts are made of resin-bonded alumina,
silicon carbide or zirconium carbide. (No Sulphurized items)
PFI-ES-43,
Section 3.3
F13
Only 300 series SS brushes are used on austenitic & nickel alloys.
PFI-ES-43,
Section 3.4
F14
All material removal & cleaning tools are marked to identify that they are
to be used on austenitic & nickel alloy materials only.
Marking is visible while a tool is in use. (Purple color code)
PFI-ES-43,
Section 3.5
F15
Austenitic & nickel alloy material fabrication areas are separated from CS
areas (upwind to prevent cross contamination).
PFI-ES-43,
Section 3.6
F16
Suitable methods prevent cross contamination by CS shavings, grinding

dust, & zinc dust from coating operations as follows:
A) Enclosure, separation & location of work areas is adequate
B) Engineering controls & ventillation
assure cleanliness & safety
PFI-ES-43,
Section 3.6
F17
Where tape is used for back purging, the tape uses an adhesive with a
water soluble chloride content not exceeding 50 ppm.
PFI-ES-43,
Section 3.7
F18
Pressure-sensitive & adhesive-backed tapes removed (along with any

residual adhesive) utilize a suitable solvent or abrasive.
PFI-ES-43,
Section 3.8
F19
Cutting fluids or oils are low halogen, low sulphur & are completely
removed from all surfaces prior to any welding or forming.
PFI-ES-43,
Section 3.9
F20
Shipping of materials utilizes new packing materials & shipping protectors

such as PVC caps, plugs, & new adhesive tapes. No harmful substances
are utilized in shipping.
PFI-ES-43,
Section 4.1
F21
Certified chloride-free marking or color coding has a water soluble

chloride content below 50 ppm (measured after drying).
PFI-ES-43,
Section 4.2
Page 9 of 21
Yes
No
N/A
Comments
Approve SS
Shop
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
F22
Identification tags & Attachment devices used are made of

noncontaminating materials.
PFI-ES-43,
Section 4.3
F23
Austenitic stainless steel & nickel alloys are shipped in a manner that will
minimize the risk of the material becoming contaminated.
PFI-ES-43,
Section 4.4
F24
Shipping alloys on same load as CS material ensures segregation

through use of wood bracing or other non-contaminating material.
PFI-ES-43,
Section 4.4
Yes
No
N/A
Comments
Equipment for Corrosion-resistant Material Welding such as austenitic

stainless steel (excluding types 304/304L/316/316L), or nickel-based
alloys meets these specific requirements:
F25
G1
A) All manual GTAW uses a high frequency start & post-purge gas flow
for the torch.
B) A remote contractor & current control (pedal or
torch mounted).
C) Pre-set
power source current start/rise and decay/stop controls triggered by a
foot switch or torch mounted control is an acceptable alternative for the
remote control.
D) O2
Analyzers & proprietary dissolvable (water soluble) dams
SAES-W-016,
Section 6
NACE & NACE Low-Temp Material Shops

NACE Material Fabrication shops are segregated from other CS.
NACE MR0175,
Section 1
G2
G3
G4
NACE Material Fabrication for NACE varieties are segregated from each
other (NACE CS, NACE Low Temp CS, NACE alloy & SS).
NACE MR0175,
Section 1
NACE Material ID is by low stress stamp & unique color-code. Segments NACE MR0175,
are stamped before cutting.
Section 1
NACE Material storage is segregated by color code. (NACE CS, NACE
Low Temp CS, etc). NACE varieties are not mixed together.
NACE MR0175,
Section 1
G5
Careful Handling of NACE materials does not create susceptibility to

Stress Corrosion Cracking in finished welds as follows:
A) Heavy
hammering is never allowed on NACE materials.
B) Identification
stamps use low-stress stamps.
NACE MR0175,
Section 1
Field & Yard Welding (Outside of a Shop)
H1
SA Inspection approves indoor facilities (shops). Welding outdoors at a

Shop facility in a yard is considered Field welding, & subject to increased
NDE extent per SAES-W-011 as applicable:
A)
Low Temp (-18C MDT) applications outdoors receive 100% NDE
B) Alloy steel (P-No. 4 & above), stainless, &
nonferrous materials (all services except Cat. D fluids) welded outdoors
are 100% NDE.
C) Severe Cycle (Cat. M) shall be
identified (100% NDE, 0 undercut)
Follow SAES-W-011
Guideline carefully based on NDT Specs
Create SPECCHECK as a field surveillance & review tool
SAES-W-011,
Section 17.5
H2
Work stations located outside of a Shop in a Yard:

A) The areas for work are properly identified as work stations.
B) Stations are level & capably support
fabricated components.
C) Sufficient
shielding & weather protection exists for stations.
D) Adequate power & remote welding controls exist for stations.
Additional NDE is required for Yard Welding
Operations.
SAES-W-011,
Section 17.5
H3
Remote Current Control use (field welding) is available for welding more
than 30 meters from power source (remote locations)
SAES-W-011,
Section 19
Procedures, Documentation & Records
Quality Plan &

Sch Q reqmt
Control of Work
I1
Approved procedures (required by Sch. Q) are available and understood

by the workers and QC.
QP
Provide
Instructions
I2
Approved WPS are posted in multiple conspicuous work areas.
QP
Provide
Instructions
Page 10 of 21
Develop &
Utilize SpecCheck ASAP on
Projects
Attachment 2
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
Yes
No
N/A
Comments
I3
Current AFC/ IFC drawings are issued & available for work
QP
Provide
Instructions
I4
Controlled record storage, i.e. offices, file cabinets, etc, is adequate
QP
Document
Quality
I5
Computer availability for record storage and back-up is adequate.
QP
Document
Quality
I6
Contractor has a filing system for the following:

Calibration records
Material receipt records, CMTRs, Mill certs, valve reports, etc
Consumables & records
Welder certs
Drawing register
Construction forms & records (spools, materials, coating, etc)
QP
Document
Quality
I7
Database per SAEP-1160 & SAIC-W-2008 for tracking and status

Weld ID system (Full Pen Butt welds, socket/groove & fillet)
Track weld special process until completion (PWHT, HT, PMI, etc)
Track welder performance
Track modifications (repairs) after
completion
Track Pressure
Tests (SAIC-A-2001 & Procedure detail steps)
SAEP-1160
Document
Quality
Valve Testing Shop
J1
Valve Testing at new shops is approved by SA Proponent as a desirable

location for any field testing prior to line installation.
J2
Proper segregation exists for CS, NACE & SS valve materials.
J3
J4
See Other
Checklist
SAES-L-108,
Section 4 4.7.1
SAES-L-108,
Section 4
An adequate water supply (treated or demin water) exists & meets SA

SAES-A-007 requirements for testing and purity.
Test Equipment is available as follows and does not promote fouling &
contamination of alloy components:
A) Pressure Test manifold rated for work per SAES-A004 reqmts.
B) Pressure hoses rated for the work
C) Water tanks, mixing
apparatus & filling hoses
SAES-L-108,
Section 4
SAES-L-108,
Section 4
SAES-L-108,
Section 4
J5
Procedure for Field Testing of Valves is approved.
J6
Personnel including QC dedicated to Valve receiving inspection & field

testing have experience with valves and have been approved.
SAES-L-108,
Section 4
J7
List of valves to be tested is available before the start of work & meets
SA standards and approved testing procedure.
SAES-L-108,
Section 4
J8
Records, QC form & unique ID numbers will exist for every valve tested.
Valves are traceable to their unique test reports.
SAES-L-108,
Section 4
See other
checklist
Coating Facility
Coating Works QC Set-up meets SAES-H-100 as follows:
A) QC Equipment Kit (SAES-H-100 Attachment A Checklist Items)
K1
B)
QC Equipment Check Sheet (SAES-H-100, Att B) available
C) In-Process Inspection Sheet (SAES-H-100, Att
C) available
D) Paints/Coatings &
Equipment Log (SAES-H-100, Att. D) available
SAES-H-100,
Section 9
K2
Ground is blacktop or marl base that will not allow dust from grade to rise
& stick to wet paint.
SAES-H-100,
Section 9
K3
Protection from the elements (sun, wind blown sand & dust, moisture) is
adequate for coating applications.
SAES-H-100,
Section 8
K4
Overspray protection (within the facility) is adequate & does not affect
other ongoing fabrication work.
PFI-ES-43,
Section 3.6
K5
Coating material storage areas meets SA & manufacturer data sheet

environmental condition requirements.
SAES-H-100,
Section 6
Page 11 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
K6
SA Inspection approved initial set-up, Qualification report & the field

demonstration & issued JCC cards to applicators.
SAEP-316,
Attachment A, B
K7
Coating Inspector qualification report & Inspector clearance card has

been issued after successful inspection during demonstration.
SAEP-316,
Attachment C, D
L1
L2
Material Handling and Storage

Pipe handling procedure including equipment used for handling is
Company approved and good practice is in effect as follows:
A) Material is not rolled/dropped
off trucks during unloading.
B) Material is stacked
properly to protect pipe and coatings.
C) Slings are nylon or
similar and wire rope slings are not used.
D) Metal hooks are padded to prevent contact damage to
coating
E) Internally coated fittings are handled on the OD only.
F) Bevel protectors
Components
from coatings.
mechanical damage with welding ends
remain intact are
andprotected
don't damage
protected with suitable wood, plastic, or metal covers and all fittings
packaged in steel-banded wooden crates or secured to skids in staging
areas for field use as follows:
A) All fittings (02-SAMSS-005, Section 10)
B) All flanges (02-SAMSS011, Section 10)
Yes
No
N/A
Comments
See other
checklist
SAES-L-450
Section 8
02-SAMSS-005
Section 10
L3
Field facilities for storage/preservation of materials are approved prior to

the start of piping installation as outlined in SAES-L-350 Section 7 and as
follows:
A) On-Plot Material Warehouse and Storage Facilities
B) Field Welding Consumable
Sch Q Attachment
Storage Facilities
IV,
C) Yard Welding Areas/Shops (CS, alloy and SS areas)
D) Spool
Storage areas, Lay Down Yards and staging areas
E) Site Valve Testing Facility, Site
Instrumentation/Testing facility
L4
The minimum amount of temporary support is available and spools are

not laying on the ground. They are supported on wooden cribbing in
approved staging areas. Fittings and valves are covered and stored in
shipping crates or on racks off the ground.
SAES-L-350
Section 7
L5
Stainless steel spools, components and other materials are kept covered
during storage in lay down yards and staging areas.
SAES-L-350
Section 7
System for Plate, Piping & Material Receipt Inspection, Material

Management & Storage
Matl Id &
Traceability
Item in QP or
Procedure
M1
A "System" used for documentation regarding ID & Traceability for spools

& structural assemblies (traceability to CMTRs) exists.
Sch Q, Att - IV
Item in QP or
Procedure
M2
CS Shop Storage areas (inside the shop) are adequate in size for large &
small materials, well marked, organized & segregated.
Sch Q, Att - IV
Item in QP or
Procedure
M3
Storage bins for cut items are marked & organized.
Sch Q, Att - IV
Item in QP or
Procedure
M4
Shop has segregated areas for reject & unusable scrap materials.
Sch Q, Att - IV
Item in QP or
Procedure
M5
Storage areas (inside the shop) are off the ground & adequate wood
(dunnage) or other supporting materials exist.
Sch Q, Att - IV
Item in QP or
Procedure
M6
Quarantine "Tagging System" used to segregate & store reject material

does not invite use of unauthorized/rejected items.
Sch Q, Att - IV
Item in QP or
Procedure
M7
Quarantine "System" Disposal Rules are in effect & disposal schedules

are available (Sch. G rules apply here also).
Sch Q, Att - IV
Item in QP or
Procedure
Matl Id &
Traceability
Item in QP or
Procedure
System for documentation (Spool ID & Traceability)
N1
COMPLETE TRACEABILITY is easily demonstrated for all components

of pipe spools & structural assemblies
Sch Q, Att - IV
Item in QP or
Procedure
N2
Traceability to CMTRs (system) is documented & well organized.
Sch Q, Att - IV
Item in QP or
Procedure
N3
Drawings & Revision Control system in place are organized.
Sch Q, Att - IV
Item in QP or
Procedure
N4
Report Records (sytem) is available for spool ID & traceability
Sch Q, Att - IV
Item in QP or
Procedure
Page 12 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
Yes
No
N/A
Comments
Sch Q, Att - IV
Item in QP or
Procedure
Data Report Contents provide adequate tracking & information. SAIC-W2008 (DATABASE) & SAIC-A-2001 (PRESSURE TESTS)
SAEP-1160
Item in QP or
Procedure
System for Identification Transfer after cutting
Matl Id &
Traceability
Item in QP or
Procedure
N5
QC forms exist for spool ID & traceability.
N6
O
O1
System (procedure) for transfer of ID BEFORE cutting exists
Sch Q, Att - IV
Item in QP or
Procedure
O2
System for transfer contains Unique Identification Numbers or UINs
Sch Q, Att - IV
Item in QP or
Procedure
O3
System can be followed by those who do not speak or write in English.

Example: Manoj is cutting two small diameter pipe lengths (different
grade CS). Small pieces can easily be mixed, misplaced, dropped or
placed in bins with other materials. Safeguards in place prevent this
occurrence. Identification methods are effective.
Sch Q, Att - IV
Item in QP or
Procedure
O4
Material markings for identification are permanent marks that remain

intact & legible on the material until recorded into QC records.
Sch Q, Att - IV
Item in QP or
Procedure
O5
Color code remains intact after cutting of pieces. System to disposition

missing & faded color coded segments exists.
Sch Q, Att - IV
Item in QP or
Procedure
Matl Id &
Traceability
Item in QP or
Procedure
Sch Q, Att - IV
Items in QP or
Procedure
Sch Q, Att - IV
Items in QP or
Procedure
Sch Q, Att - IV
Items in QP or
Procedure
Sch Q, Att - IV
Items in QP or
Procedure
P
P1
P2
P3
P4
Color Coding Verification Upon Receipt

Disposition rules for missing & faded (unidentifiable or questionable
grade) color coded piping & materials exist.
Quality Control (verification) is always performed upon receipt.
Only Quality Personnel may approve repainting after the following:
Materials have been verified (CMTR & UIN) for distinct color code.
Quality Control documentation & issuance of
NCR against Vendor
Notification
& approval from Saudi Aramco is received
Positive Material Identification verifies composition (alloy, SS
items)
Material Receiving Inspection personnel (quality) are adequately trained
and can identify missing, faded and improper (mixed) color coded items
that arrive on site.
P5
Repainting is done with correct RAL paint per applicable SAMSS

requirement (length & size of striping).
Sch Q, Att - IV
Items in QP or
Procedure
P6
Positive Material Identification (PMI) is witnessed.
Sch Q, Att - IV
Items in QP or
Procedure
System Identification (Pipe Spools, Pipe Lengths, etc)

After Sandblasting & Coating
Matl Id &
Traceability
Item in QP or
Procedure
Q1
System for Identification after sandblasting/coating exists
Sch Q, Att - IV
Items in QP or
Procedure
Q2
System prevents sandblasting removal of UINs (Unique Identification

Numbers) & resulting loss of traceability
Protective tape covering stamp identifcation
adjacent to weld
Marking inside spools with permanent marker (systematic marking)
Application of wire & stamped tags showing spool or segment UIN
Sch Q, Att - IV
Items in QP or
Procedure
Q3
System protects UINs after coating

Remarking restrictions (QC notified) are identified
Stamped tag identification method is employed
Verification of UIN is performed by QC
Sch Q, Att - IV
Items in QP or
Procedure
System Controls for Special Process (NDE, PMI, PWHT, etc)
R1
System of checks & control is in place for materials requiring special

processes (NDE, PMI, PWHT, BHT, etc). Spool Clearance!!!
Sch Q, Att - IV
Items in QP or
Procedure
R2
Personnel are trained & understand this system of control
Sch Q, Att - IV
Items in QP or
Procedure
R3
Identification status through special flagging & marking systems can

physically identify spools & materials:
A) Requiring a special process
B) Completed and accepted special
process
C) Completed and
rejected special process
Sch Q, Att - IV
Items in QP or
Procedure
Page 13 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
ACCEPTANCE CRITERIA
No. System Documentation & Tracking Records are in place to identify all
material special processes required before fabrication:
A) Spool tracking & clearance Sheets
B) NDE
R4 Clearance (RT Trackers, RT Backlog Control, etc)
C) Coatings
Application Tracking
Isolation rules & methods are employed for special processes:
A)
Segregation employed is effective
B) Signs & barricade warning tape exist (segregated areas)
RT pending Laydown & Staging
R5
Areas
PWHT pending Laydown & Staging Areas
Coating Pending Laydown & Staging
Areas
REFERENCE
Yes
No
N/A
Comments
Schedule Q &
SAEP-1160
Database
Reqmts
Items in QP or
Procedure
Sch Q, Att - IV
Items in QP or
Procedure
R6
Hold status (tagging, etc) system exists & is understood to prevent

shipments of materials & spools not accepted by Quality.
Sch Q, Att - IV
Items in QP or
Procedure
R7
Completed Spool Staging Area(s) (Ready to ship, etc) exist.
Sch Q, Att - IV
Items in QP or
Procedure
Piping spools (assemblies) are checked, cross referenced & clearly

marked after in-process verification of dimensional requirements.
Schedule Q &
Fit-up OK, Inspector initial & date,
SAEP-1160
etc
Database
Visual weld (VT) OK, Inspector initial & date
Reqmts
Final Dimensional check (Final) OK,
Inspector initial & date
Items in QP or
Procedure
S1
T1
T2
T3
T4
T5
System Controls for In-Process Spools
In-progress Radiographic Testing & Reporting Controls

RT selection process has the highest integrity possible
Subcontractor QC does not exclusively select welds to be RT'd.
Contractors maintain tight control over selection of Random RT.
Subcontractor &
Contractor QC work together in selection & invite Company QA personnel
into the process in a spirit of Teamwork.
RT Selection Process is closely watched & monitored
RT shooting lists are available & system is monitored as follows:
Daily RT Shoot List is always
available to Contractor & Company
RT Shoot List Results (previous day) are checked every day.
Tracking of Reject welds &
reshoots are carefully monitored
Penalty
shot selection is carefully monitored
Defect location marking is carefully performed & monitored
Daily RT shooting lists with Reshoots (film & weld quality) identify shots
as follows:
The cause of
the Reshoot is identified (in writing) on the Shoot list.
Penalty shots are identified on the list.
Repair attempts (R1or R2) are identified on the
Shoot list.
RT Clearance (Repaired welds, reshoots, penalty shots) are closely
monitored by Contractor
Poor welder performance is identified very early in the
process.
Poor RT technique &
performance is identifed & corrected early.
RT Clearance is verified by SA Level III at the earliest opportunity.
RT Backlog is closely monitored by Contractor & Subcontractor.
Backlog goals
are set & maintained early in the project.
System of tracking reports RT Backlog numbers regularly (weekly)
Backlogs exceeding 100 joints receive
immediate attention to clear
Sch Q, Att - IV
Guide for
approval of NDT
control
Procedures
Sch Q, Att - IV
Guide for
approval of NDT
control
Procedures
Sch Q, Att - IV
Guide for
approval of NDT
control
Procedures
Sch Q, Att - IV
Guide for
approval of NDT
control
Procedures
Sch Q, Att - IV
Guide for
approval of NDT
control
Procedures
System Controls
U1
Tracking System for organization of material & storage is in place

(Demonstrate how a piece of pipe and fittings become a spool)
Sch Q, Att - IV
U2
Signs in Segregated Areas exist (materials, warnings, etc)
Sch Q, Att - IV
U3
Segregation Area rules exist and are followed.
Sch Q, Att - IV
U4
Material Receiving Personnel are of adequate number & are properly

trained and available.
Sch Q, Att - IV
Page 14 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
U5
QC Inspection Personnel are adequate in number per Sch. Q & are

properly trained & approved by Company prior to start of work.
Sch Q, Att - IV
U6
Tracking system for spools is available (QC tracking lists, etc)
Sch Q, Att - IV
U7
Color Coding system is approved (PFI-ES-22 & SAES-A-206)
Sch Q, Att - IV
U8
Material Storage Yard is level and properly compacted or asphalted
Sch Q, Att - IV
U9
Pipe racks or supports (metal, wood) are adequate to provide full support
to new piping (3 to 4 sets) with no bowing or sagging
Sch Q, Att - IV
U10
Material Receiving Yard is of adequate size for significant quantities of

piping to be received
Sch Q, Att - IV
U11
Safety Signs (access/egress/overhead crane/etc) exist
Sch Q, Att - IV
U12 Overhead crane construction is complete and approved by SA.
Sch Q, Att - IV
U13 Overhead crane certification is available to SA Safety & Insp.
Sch Q, Att - IV
V1
V2
W1
Yes
No
N/A
Comments
System Controls for Handling Materials

The System used for handling all types of materials meets minimum
industry requirements and good practice
Equipment is properly outfitted to handle a variety of materials:
Stainless & alloy materials are not
directly handled with CS
Coated materials & spools employ equipment protection
coverings
Sch Q, Att - IV
Sch Q, Att - IV
Material Warehouse & Controlled Climate Storage
5 M + E (Coating Consumables, Welding Electrodes, etc)
Sch Q, Att - IV
Equipment Check Points
X1
Proper cleaning equipment (tools) for all diameter piping fabrication is

available at the shop in adequate numbers as follows:
A) Variety of grinders (internal, external
prep of metal surfaces)
B) Attachments (grinding wheels, cones, stones, flappers, etc)
C) Slag hammers, chipping tools, brushes
(Each worker)
D) Adequate
rags, cleaning solvents (Storage Room Control)
X2
Demineralized water (treated water) supply exists for SS shops
X3
Drills (various size) & presses are adequate in their number & condition
for small diameter pipe openings. (No torches allowed)
X4
Internal machining tools (beveling, preparation) provide a quality surface PFI-ES-21,

finsih & allow fit-up of GTAW process butt welds
Section (All)
X5
Bending equipment is available & in good condition.
X6
Procedure for pipe bending methods is approved (by CSD).

A) Hot bending methods (Furnace, Incremental, & Induction
bending)
PFI-ES-24,
B) Cold bending methods (Rotary draw, ram & roll bending)
Section (All)
C) Bends are examined, protrusions repaired (VT, MT/PT,
UT) & gauging internals is performed (deformation, 97.5% nominal id)
X7
Pipe ovality repair tools (jacks, crescents*) for repairs to 3% out.

PFI-ES-24,
* SMYS values are not exceeded. A 30-ton jack
Section (All)
for CS (maximum)
X8
Pipe ovality repair procedure is approved & details equipment.
PFI-ES-5,
Section (All)
PFI-ES-05,
Section 4
PFI-ES-21,
Section (All)
PFI-ES-24,
Section (All)
Sch Q, Att - IV
Page 15 of 21
Manufacturer
recommended
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
DISCIPLINE
30-Apr-13
WBS/BI/JO NUMBER
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
X9
Demineralized/Treated water supply (tank) exists for SS shop.
X10
Flapper wheels to obtain ID cleanliness needed. Solvents for degreasing

PFI-ES-5,
and cleaning piping after cutting operations needed.
Section (All)
See PFI ES-5
X11
Bevel machines are in good condition. Means to meet groove weld

parameters is acceptable to Company & gauges are available
Y1
Y2
Yes
No
QP
N/A
Comments
scope of work
QP
scope of work
QP
Items in QP or
Procedure
QP
Items in QP or
Procedure
Measuring & Test Equipment (M&TE) for Welding

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

PRIME CONTRACTOR QA/QC MGR INTERVIEW TO TASK THEM TO ASSURE A SMOOTH
QUALITY START ON PROJECTS
REFERENCE DOCUMENTS:
Contract Schedule Q (Date Variable) Quality Assurance and Control, Inspection and Testing
01-SAMSS-010 - Fabricated Carbon Steel Piping (25 May 2011)
02-SAMSS-005 - Butt Welding Pipe Fittings (20-Feb. 2012)
012-SAMSS-008 - Erection of Structural and Miscellaneous Steel (9-May 2011)
SAEP-1141 - Industrial Radiation Safety (8-Dec-2010)
SAEP-323 - Performance Qualification Testing of Contract Welders and Brazers (01 July, 2008)
SAES-A-206 - Positive Material Identification (30-April 2011)
SAES-H-200 - Storage, Handling and Installation of Externally Coated Pipe (24 Oct 2011)
SAES-L-310 - Design of Plant Piping (29 April, 2007)
SAES-L-350 - Construction of Plant Piping (22 April 2009)
SAES-W-011 - Welding Requirements for On-Plot Piping (4-Oct. 2009)
ANSI/AWS Z49.1 - Safety in Welding, Cutting & Allied Processes (January 2004 Edition)
ANSI/AWS D1.1-96 - Structural Steel Welding Code (2004 Edition)
ASME B31.3 - Process Piping (2010 Edition)
NACE Standard MR0175 - Sulfide Stress Cracking Resistant Metallic Materials (2002 Edition)
NACE Standard RP0472 - Methods & Controls (Prevent In-Service Cracking of CS Welds in Corrosive Environments (2000)
PFI (Piping Fabrication Institute) Standard ES-01 - Internal Machining for Circumferential Butt Welds (2001 Edition)
PFI Standard ES-02 - Method of Dimensioning Piping Assemblies (2000 Edition)
PFI Standard ES-03 - Fabrication Tolerances (2000 Edition)
PFI Standard ES-05 - Cleaning of Fabricated Piping (1999 Edition)
PFI Standard ES-11 - Permanent Marking of Piping Materials (1998 Edition)
PFI Standard ES-21 - Internal Machining & Fit-up of GTAW Root Pass Circumferential Butt Welds (2001 Edition)
PFI Standard ES-22 - Color Coding of Piping Materials (1999 Edition)
PFI Standard ES-24 - Pipe Bending Methods, Tolerances, Process & Material Requirements (2001 Edition)
PFI Standard ES-26 - Welded Load Bearing Attachments to Pressure Retaining Piping Materials (1999 Edition)
PFI Standard ES-27 - "Visual Examination" The Purpose, Meaning & Limitation of the Term (2000 Edition)
PFI Standard ES-31 - Standard for Protection of Ends of Fabricated Piping Assemblies (2000 Edition)
PFI Standard ES-32 - Tool Calibration (2000 Edition)
PFI Standard ES-37 - Standard for Loading & Shipping of Piping Assemblies (2000 Edition)
PFI Standard ES-41 - Standard for Material Control & Traceability of Piping Components (1998 Edition)
PFI Standard ES-43 - Standard for Protection of Austenitic Stainless Steel & Nickel Alloy Materials (1999 Edition)
Page 16 of 21
SAIC NUMBER

DATE APPROVED
SAIC- L-2031
PROJECT TITLE
WBS/BI/JO NUMBER
DISCIPLINE
30-Apr-13
EQUIPMENT ID NUMBER
EQPT CODE
SYSTEM
REV. NO.
S/U SYSTEM
FACILITY
K. Raja Roa
RFI No.
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
Contractor
Yes
No
N/A
Saudi Aramco
Construction Rep.
Name, Initials, & Date:
PMT Representative:
Verified Reviewed
QC Inspector
Name, Initials & Date:
PID Representative:
Verified Reviewed
QA/QC Supervisor
Name, Signature & Date:
Proponent and Others:

Verified Reviewed
*Person Responsible for Completion of Quality Work / Test
Y = YES
Page 17 of 21
N = NO F = FAILED
Comments
Page 18 of 21
Page 19 of 21
Page 20 of 21
Rev 5
8/31/2010
8/31/2011
Page 21 of 21

Saudi Aramco Inspection Checklist

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2012)

SAUDI ARAMCO INSPECTION CHECKLIST

LAYOUT DRAWING NUMBER

REQUESTED INSPECTION DATE

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

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

Use this guide

Special Process Procedure Revision Approval is received BEFORE

CSD has the

SAUDI ARAMCO INSPECTION CHECKLIST

LAYOUT DRAWING NUMBER

REQUESTED INSPECTION DATE

WPS Drawing Details (CSD common revisions):

WPS Miscellaneous details (CSD common revisions):

NDT/NDE Technique procedures have been Dhahran approved

Equipment & Set-up (See SAES-H-100 Checklists A,

NDT/NDE CONTROL procedures are issued and clear for all

Sch. Q, Att. IV,

Sch. Q, Att. IV,

Sch. Q, Att. IV,

SAUDI ARAMCO INSPECTION CHECKLIST

LAYOUT DRAWING NUMBER

REQUESTED INSPECTION DATE

Heat Treatment (associated process) requirements:

Contractor has good supply of "Certified" test bars (194, 200+)

Welder Qualification Testing

Prior to welder qualifications, Shop Controls are established for welder

Welder Testing (Procedures & Controls) are approved:

Sch. Q, Att. IV,

Machine spacing & clearances (layout) is adequate and safe.

Welding Procedure Controls for Low Temp Applications:

Best welders selected (Consistently meet Heat Input & Hardness)

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

Welding on NACE material is performed as follows:

Work stations for each welder are checked as follows:

Welder training & testing areas are segregated or in a separate area

Welding machines for each work station have current calibration

SAUDI ARAMCO INSPECTION CHECKLIST

LAYOUT DRAWING NUMBER

REQUESTED INSPECTION DATE

Welding machines (singular or banked) have sufficient spacing and

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

ANSI Z87.1 &

Welding Facilities (Environmental Shielding) provides adequate

Welding equipment set-up & testing is complete:

Sch. Q, Att. IV,

Welding Electrode & Consummable Storage:

Calibrated weld rod holding ovens are set up & controlled:

Pressurized gas cylinder (consumable) storage:

SAUDI ARAMCO INSPECTION CHECKLIST

LAYOUT DRAWING NUMBER

REQUESTED INSPECTION DATE

Shop has a Tungsten grinder (diamond cutting/grinding/shaping) &

Construction Manpower Forecast (start-up & peak) showing total

QC MANPOWER FORECAST (start-up & peak) showing total number of

QC Manpower meets Construction manpower ratios.

CV-approved Quality personnel arrive early* (10-days before work) for

Quality Personnel experience minimum requirements (Contractors or

Heat Treatment Inspector:

Coating Inspector: Inspector demonstrates a thorough working

All IK CONTRACTOR & subcontractor NDT personnel performing NDT

Quality Assurance Manager is approved:

SAUDI ARAMCO INSPECTION CHECKLIST