Saep 1150

Engineering Procedure
SAEP-1150 Inspection Coverage on Projects Document Responsibility: Inspection Department 1 July 2008
Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 Scope............................................................. 2 Applicable Documents................................... 2 Definitions...................................................... 5 Inspection Department (ID) Responsibilities.. 6 Inspection Assessment Group (IAG) Responsibilities...................................... 8 6 Vendor Inspection Division (VID) Responsibilities...................................... 9 7 Operations Inspection Division (OID) Responsibilities.................................... 13 8 Projects Inspection Division (PID) Responsibilities.................................... 15 9 Inspection Department Reporting Responsibilities.................................... 23 10 Deviations to Company Requirements......... 28 Appendix A - Instructions for PID Coverage...... Appendix B - Typical Inspection Points.............. Appendix C - Logbook Format........................... Appendix D - (PQI Format Procurement Phase)............................ Appendix D - (PQI Format Construction Phase)............................ Appendix D - (PQI Format - Summary Sheet)... 30 41 47 48 49 50
Previous Issue: 30 June 2004 Next Planned Update: 1 July 2013 Page 1 of 50 Primary contact: Supervisor, IEU on 874-6604
CopyrightSaudi Aramco 2008. All rights reserved.
Document Responsibility: Inspection Department Issue Date: 1 July 2008 Next Planned Update: 1 July 2013
SAEP-1150 Inspection Coverage on Projects
Scope This Saudi Aramco Engineering Procedure (SAEP) defines the responsibilities and activities of the Inspection Department (ID) on all Saudi Aramco capital projects. This procedure provides a summary of the major quality management activities of the ID during all phases of new projects.
Applicable Documents The requirements contained in the following documents apply to the extent specified in this procedure. 2.1 Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-14 SAEP-122 SAEP-133 SAEP-302 SAEP-303 SAEP-309 SAEP-316 SAEP-318 SAEP-319 SAEP-324 SAEP-352 SAEP-1131 SAEP-1140 Project Proposal Project Records Instructions for the Development of Regulated Vendor Lists Instructions for Obtaining a Waiver of a Saudi Aramco Engineering Requirement Engineering Reviews of Project Proposal and Detail Design Documentation Inspection of Community and Operations Support Facilities Performance Qualification of Coating Personnel Pressure Relief Valve Authorization for Installation, Deletion and Changes Pressure Relief Valve Routine Test, Inspection, Quality Assurance and Regulation Certification Review and Registration of Project Welders and Brazers Welding Procedures Review and Approval Pressure Relief Valve Program Use of Form 3099-A-ENG, RV Authorization Qualification and Certification of Saudi Aramco Nondestructive Testing Personnel
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SAEP-1141 SAEP-1142 SAEP-1152
Industrial Radiation Safety Qualification of Non-Saudi Aramco NDT Personnel Approval procedure for Ready-Mixed Concrete Mix Design
Saudi Aramco Engineering Standards SAES-A-004 SAES-A-005 SAES-A-007 SAES-A-206 SAES-H-101 SAES-J-600 SAES-L-350 SAES-P-104 SAES-Q-001 SAES-Q-006 SAES-T-Series SAES-W-Series SAES-X-Series General Requirements for Pressure Testing Safety Instruction Sheet Hydrostatic Testing Fluids and Lay-Up Procedures Positive Material Identification Approved Protective Coating Systems Pressure Relief Devices Construction of Plant Piping Wiring Methods and Materials Criteria for Design and Construction of Concrete Structures Asphalt Concrete Paving Communications Standards Welding Standards Cathodic Protection Standards
Saudi Aramco General Instruction GI-0002.703 Electrical Load Planning and Connection/ Disconnection of Loads to Saudi Aramco's Distribution System Certification of High Voltage Cable Splicers Mechanical Completion and Performance Acceptance of Facilities Ionizing Radiation Protection Quality Management Roles and Responsibilities
GI-0002.705 GI-0002.710 GI-0150.003 GI-0400.001
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Saudi Aramco Inspection Requirements SAER-1972 Saudi Aramco Materials Inspection and Testing
Saudi Aramco Inspection Procedures 00-SAIP-10 00-SAIP-12 00-SAIP-13 IAG-01 VID-M-016 Non-Conformance Reports Equipment Deficiency Report Projects Assessment Procedure Internal Assessment SAIR Procedures
Saudi Aramco Inspection Forms VID-3000 VID-8635 2093 2642 3099-A-ENG 4758 6133 6717-ENG 8233-2 Request for Monitoring of Contractor's Source Inspection Equipment Deficiency Report Equipment Inspection Record - General Pressure Test Report Relief Valve Authorization Welder Job Clearance Card Exception Item List Request for Inspection Splicer Job Clearance Card
Saudi Aramco Standard Contracts Schedule A Schedule B Schedule C Schedule E Schedule F Schedule G Schedule H Schedule Q Drafting Manual
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General Terms and Conditions Job Specification Contract Price and Payment Provisions Settlement of Disputes, Arbitration, and Choice of Law Taxes, Duties, and Related Obligations Materials, Tools and Equipment Special Terms and Conditions Project Quality Requirements
2.2
Industry Standards and Codes International Standards Organization ISO 9000 Quality Management System - Fundamentals and Vocabulary
Definitions For the purposes of this procedure, the following definitions apply. Further quality definitions can be located in ISO 9000. Quality System: Organizational structure, procedures, and processes and resources needed to implement quality management. Monitoring: The observation, verification and recording of specific design, procurement, construction and inspection activities while in process to ensure that work is performed in accordance with the applicable standards and specifications. Proponent: The Saudi Aramco organization responsible for the final acceptance and operation of the facilities being constructed. Inspection & Test Plan (I&TP): An I&TP is a document based on the detailed manufacturing, fabrication and construction program which identifies each process description, sets out the related sequence of activities to be inspected, examined and tested and lists the relevant approved procedures for a particular material, component, assembly, or, in some cases, type of work. It shall include identification of requirements for documents, acceptance criteria to be used, who is responsible for what, the inspection surveillance to be performed and the type and level of inspection including hold, witness and review points of Contractor/Sub-contractor and Saudi Aramco. Mandatory Hold Point: An inspection point, defined in an appropriate document, beyond which an activity must not proceed without the approval of a designated organization or authority. Witness Point: An inspection point, defined in an appropriate document, beyond which an activity can proceed after notifying the designated organization or authority. Contractor's QC Inspector has full responsibility for performing detailed inspections during the work activity. Review Point: A review point, defined in an appropriate document, is the point at which a work activity cannot proceed without first ensuring the review and approval of applicable documents or personnel qualifications by a designated organization or authority.
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Non-Destructive Testing (NDT): Non-destructive Testing covers the use of any recognized NDT method for which established International Certification Programs approved by Saudi Aramco exist. Other NDT methods may be used providing approval is given by the Department's head NDT level III and practical performance verification is performed successfully. Quality Assessment: Generally replaces the term 'Quality Audit'. A systematic and independent examination to determine whether quality activities and related results comply with planned arrangements and whether these arrangements are implemented effectively and are suitable to achieve objectives. Quality Assurance (QA): All the planned and systematic activities implemented within the quality system, and demonstrated as needed, to provide adequate confidence that an entity will fulfill requirements for quality. Quality Control (QC): The operational techniques and activities that are used to fulfill requirements for quality. Quality Control Procedure (QCP): A QCP is a documented procedure detailing the processes necessary to complete a specific work activity. Request for Inspection (RFI): An Inspection Department (ID) document (Saudi Aramco Form 6717-ENG) used by SAPMT to request inspection. Short Form Contracts (SFC): Generally, short form contracts are used where the total estimated value of the work is less than SR 500,000 and the duration of the work is less than 6 months. 4 Inspection Department (ID) Responsibilities The Inspection Department's responsibilities are covered by the ID Mission Statement and strategies as published on the ID Intranet web page. 4.1 The Inspection Department's responsibilities on Projects include: 4.1.1 Provide QA for Capital Projects to ensure contractor's quality personnel and processes are effective, and that new facilities are constructed in compliance with applicable Company and Industry engineering standards, and Company policies and procedures. Provide QA services in all facets of the Company's Supplier Qualification and Material and Equipment acquisition. Provide QA services that ensure Industrial Radioactive Equipment is maintained, stored and operated safely at all times, and that all NDT personnel are adequately trained and certified for the work they perform.
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4.1.2 4.1.3
4.1.4 4.2
Provide Quality Assurance services that ensure the safe operation of all lifting equipment working on Company facilities.
Responsibilities of Other Organizations ID's involvement on a capital project does not relieve SAPMT, the vendor, manufacturer, or the contractor of the responsibility to comply with Scope of Work requirements, all Saudi Aramco Standards and specifications, mandatory Standard Drawings, Company adopted National or International Codes and Standards and Project Specifications.
4.3
Quality System, Products and Facilities Monitoring The ID shall monitor and assess the Quality Management system and Products/Facilities being supplied by the Vendor/Contractor/Fabricator in accordance with Saudi Aramco Standards, Purchase Orders, and/or Schedule Q. Material inspection levels shall be defined in accordance with SAER-1972 and Schedule Q.
4.4
Extent of QA/QC Coverage ID provides QA and/or QC services for Saudi Aramco throughout the various phases of the project, i.e., proposal, design, procurement, fabrication, and construction. This is accomplished through direct inspection, monitoring and quality assessments as required.
4.5
Assignment of Personnel ID starts their involvement in projects by reviewing Design Basis Scoping Papers and Project Proposals. ID will assign a Project Quality Manager during project proposal who will be supported by additional ID personnel at the design offices and construction sites per the following Matrix: Inspection Representation
Project Proposal Development
Bid Explanation Meeting
Technical Bid Evaluation
Design & Procurement Kick-Off Meeting
Design Phase
Procurement Phase
Construction Kick-off Meeting
Construction Phase
PreCommissioning Phase
VID OID PID IAG PQM
X(1) X
(1)
X(2) X
(2)
X(5) X X
(5) (5) (5) (5)
X X
(3)
X X(4) X X X X X(4) X X X X X
X X X X
X X X
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Notes: 1. 2. 3. 4. 5. Attachment VI of Schedule Q, Novaited POs, and Project Quality Plan. Presentation of quality requirements (PID/VID as required). PID reviews design packages. OID reviews NDT procedures and technician certifications. As requested by SAPMT
4.6
Project Quality Manager (PQM) On all major projects or a group of small projects, ID will assign a Project Quality Manager (PQM) in accordance with GI-0400.001, who shall be responsible for planning, executing, and controlling all quality management activities on the project. The PQM is also responsible for promoting and building awareness of the Project's quality requirements. All personnel that are assigned to capitol projects shall be thoroughly familiar with ISO 9001:2000. More details on the roles and responsibilities of PID shall be provided in the project specific quality plan. The PQM shall advise SAPMT of the need for PQM concurrence prior to contract issuance.
4.7
Project Quality Plan (PQP) During project proposal, a detailed Project Quality Plan will be prepared jointly by SAPMT and the PQM as defined by GI-0400.001 and SAEP-14 (refer to PQP Template, available on the Inspection Department website). The PQP will, among other things, outline the Saudi Aramco Inspection Team manning levels and mobilization schedule, define the relationship between Inspection and SAPMT, define project objectives and responsibilities, and outline authorities and channels of communication.
Inspection Assessment Group (IAG) Responsibilities Inspection Assessment Group's main responsibility on capitol projects is to perform independent External and Internal quality assessments on capital projects as per 00-SAIP-13 and IAG-01 respectively. Inspection Assessment Group's primary functions: 5.1 5.2 5.3 Perform quality assessments of contractors' quality programs on LSTK and LSPB capital projects. Perform internal assessments on the activities of Inspection teams and Saudi Aramco Inspection representatives assigned to LSTK and LSPB capital projects. Perform assessments of other internal and external organizations when requested.
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5.4 5.5 5.6 5.7
Compile and report the monthly Project Quality Indices for all applicable projects (PQI). Provide specialized assistance to Projects Inspection and Vendor Inspection Divisions on project quality requirements. Lead Inspection Department's quality enhancement activities. Perform quality assurance reviews of comments generated during review of Contractor quality plans.
Vendor Inspection Division (VID) Responsibilities VID provides quality monitoring and inspection support for projects during the proposal and design & procurement phases to ensure compliance with schedule Q requirements, Saudi Aramco Standards and Specifications. VID shall conduct quality monitoring and participate in surveys & assessments of vendors with the contractors as needed to assist SAPMT during design and procurement activities. 6.1 Saudi Aramco Inspection Representative Requirement VID will determine its vendor inspection representation requirements to monitor the Contractor's QA/QC activities in accordance with GI-0400.001 and internal procedure VID-M-016. For major projects, the assigned SAIR will usually be located with SAPMT at the Contractor's design/procurement office. The SAIR will work independent of schedule and cost decisions. He reports to PQM and/or SAPMT depending on his location and size of the project as detailed in GI-0400.001. He is primarily responsible for SAPMT interface, problem solving, interpretation of Company standards, promoting and building awareness of project quality requirements among the project team and Contractors, communication of previous lessons learned, development of effective preventive actions system with Contractors and Vendors, and providing assistance in resolving issues relating to project quality. All formal communications with the Contractor shall be through the Company Representative. The SAIR may be assigned to the site office during the construction phase to follow-up on remaining procurement and material receiving activities. 6.2 Vendor Inspection Division Coverage 6.2.1 Project Proposal Stage VID may be involved, but shall not be limited to, participation in the defining of material inspection levels, development of PQP, review of
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novated orders, and bid evaluation. 6.2.2 Bid Explanation Meeting In coordination with the PQM, VID shall attend project bid explanation meetings. They shall focus the Contractor's attention on the requirements of Schedule Q for design and procurement. If required, they will also present all items of concern from OID and PID. A list of items or a presentation of project quality requirements should be developed and reviewed with SAPMT prior to the meeting. 6.2.3 Design/Procurement Kick-Off Meeting VID shall use this meeting as a starting point to briefly reintroduce major topics from the Bid Explanation meeting to the Contractor with regards to Schedule Q. Following this, and as soon as practical, VID shall conduct a quality system orientation and provide guidance on the use and implementation of Schedule Q and SAER-1972 (SA-175's) to SAPMT and Contractor personnel. 6.2.4 ID Quality System Assessments For all projects exceeding $50 MM, the PQM will coordinate with the Inspection Assessment Group (IAG) in developing a schedule of assessments to be performed on Contractor Quality Systems during the design& procurement phase of the project. A VID representative should participate in these assessments and attend the opening and closing meetings as an observer and provide assistance as required. VID should follow-up on Corrective Action Request (CARs) generated by these assessments. On all other projects, the VID representative, PQM, or the SAPMT Project Manager may request assessments of the Contractor's quality system when deemed appropriate. 6.2.5 Quality Plan Reviews; Design, Procurement and Construction In coordination with the PQM, VID shall ensure that Contractor's and major sub-Contractor's procurement Quality plans and inspection procedures are prepared in accordance with Schedule Q. Comments shall be forwarded to SAPMT for resolution with the Contractor. If SAIR is located at OOK contractor office, then he shall assist to ensure that Construction related Quality plans, inspection procedures, and inspection checklists are forwarded to PQM for review and comment.
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6.2.6
Quality Personnel Qualifications VID shall review the qualifications and experience of the Contractor's QC personnel related to Design and Procurement phases, against the criteria specified in Schedule Q. Where appropriate, QC personnel shall be interviewed and/or subjected to examination, by Vendor Inspection or their designated representatives. Approval of all contractor's procurement QA/QC personnel shall be as per Schedule Q requirement. Approval of contractor QA manager covering design, procurement and construction phases shall be in coordination with the PQM.
6.2.7
Design Reviews VID will ensure that Contractor perform design reviews at the appropriate stages as indicated in their quality plan and maintain records of such reviews in accordance with Schedule Q. For projects that contractor office is located OOK, VID shall represent the ID during the scheduled Design Review meetings at the Contractor's design office.
6.2.8
Review of Purchase Documents VID shall review purchase requisitions and other similar documents to verify application of the appropriate Company Standards and Inspection Requirements. VID will initiate comments to SAPMT with all PR deficiencies and recommended corrective action as needed.
6.2.9
Supplier Qualifications VID shall review proposed vendors to ensure the manufacturers have been properly qualified by the Contractor in accordance with Schedule Q. During the PIM, previous lessons learned related to the Vendor and/or the materials being supplied, shall be discussed.
6.2.10
Pre-inspection Meetings VID or one of their designated inspection offices shall attend Preinspection Meetings (PIM) if required. The meeting shall address all quality related requirements of the purchase order. During the PIM, the detailed inspection and test plan (ITP), which include inspection hold, witness, and review points, shall be reviewed and finalized.
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6.2.11
Manufacturing Procedures When required by Company standards, VID shall ensure that relevant supplier procedures such as refractory installation, welding, welding repair, NDT, heat treatment, and alloy verification as applicable, are reviewed and approved by Saudi Aramco prior to the vendor's start of any of these activities or as specified in Schedule Q and VID-M-016.
6.2.12
Quality Monitoring on LSTK and LSPB Contracts 6.2.12.1 Criteria for Monitoring POs VID shall review and determine which purchase orders to monitor. VID shall select vendor activities to be monitored on the basis of Company inspection requirements, vendor history, information received from the Contractor, such as ITPs. 6.2.12.2 Inspection Monitoring Requests Contractor's source inspection activities will be monitored by VID or by one of the Saudi Aramco Inspection office (AOC-L, AOC-T, ASC). This is done by initiating an inspection lot in SAP as detailed in the internal procedure VID-M-016. Special requirements (i.e. request to attend pre-inspection meetings, interviews and qualification of inspectors) shall be indicated on the inspection lot. The assigned inspection office shall review the request package and arrange with VID on appropriate coverage. 6.2.12.3 Review of Major Sub-Orders VID shall monitor the Contractor's review of major suborders to ensure relevant Saudi Aramco Standards and Specifications have been passed along to the sub-suppliers. 6.2.12.4 Quality Assessments VID shall review the Contractor's internal and supplier assessments for design and procurement phases, and monitor results on an ongoing basis. VID representative may attend the Contractor's assessments as an observer. If necessary, VID may conduct their own independent assessments and forward their findings to SAPMT for resolution with the contractor.
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6.2.13
Equipment Deficiency Reports (EDRs) VID has the responsibility to ensure that EDRs are handled consistently and that proper feedback is provided to EDR/PO Originators, vendor, or other appropriate organization as applicable to prevent recurrent deficiencies.
Operations Inspection Division (OID) Responsibilities OID's quality activities on new construction projects are generally limited to NDT procedures, NDT assessments, NDT technician certifications, radiation safety, lifting devices (Cranes, slings, etc.), and pressure relief valves used on all Company property. In addition, OID is responsible for inspection coverage of repair and new construction that is Proponent managed in the Dhahran area. 7.1 Notification of NDT Activities For effective planning and timely support, OID/NDT Unit will maintain close contact with PID to obtain the name and the date of mobilization for NDT subcontractors. See paragraph 8.12. 7.2 OID NDT Services 7.2.1 Technical Responsibilities a) b) c) d) e) f) g) h) 7.2.2 Review Contractor NDT procedure for personnel NDT qualification for compliance with SAEP-1142. Administer all practical NDT examinations for IK NDT Contractors. Review and approve all NDT procedures for each project. Conduct Radiographic Film Interpretation assessments. Conduct assessments of Contractor NDT and report performance. Assist PID in resolving disputes on NDT results. Support PID in performing NDT as requested. Provide NDT Level III services to Saudi Aramco organizations as needed.
Radiation Safety Responsibilities a) Review and approve the IK NDT Contractor's Radiation Safety Plan for compliance to SAEP-1141 and GI-0150.003.
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b) c)
Interview and approve the IK Contractor's Radiation Safety Officer (RSO). Issue a "Saudi Aramco Radiographer Permit" for individuals successfully passing the Loss Prevention Radiation Safety Examination. Issue radiation safety Advisories and Alerts, as and when required. Review and approve radiation source type used for radiography, equipment used for handling, transporting, and storing radioactive material, radiation monitoring devices, and methods of reporting. Inspect and approve IK radiation isotope storage pits located on Company property. Perform unannounced radiation safety assessments. Investigate Contractor incidents occurring on Company property and report in accordance with the requirements of SAEP-1141 and GI-0150.003.
d) e)
f) g) h)
7.3
Cranes, Elevators, and Lifting Equipment OID shall follow their internal procedures for the inspection of all cranes, elevators, below-the-hook lifting equipment owned and operated by Saudi Aramco or by Contractors and used on Saudi Aramco projects, for compliance with Saudi Aramco Safety Standards and relevant GIs. Cranes and elevators that conform to these standards will have an inspection sticker affixed. Belowthe-hook lifting equipment will be marked with the safe working load and ID number, unique to that particular piece of equipment, either by tagging or stamping prior to acceptance by OID.
7.4
Pressure Relief Valves Registration Registration of Pressure relief valves shall be administered by OID per SAEP-318, SAEP-319, and SAEP-1131.
7.5
Dhahran Facilities Inspection Group Responsibilities 7.5.1 The Dhahran Facilities Inspection Group (DFIG) is responsible for inspection coverage of proponent managed BI-1900/Work Order projects which involve repair, renovation, upgrading, and new construction of Community and Operations support facilities in the Dhahran area per SAEP-309. Civil, Electrical, Mechanical, and Plumbing/HVAC inspection guidelines for DFIG shall be similar to PID Chapter 8/Appendix A and
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7.5.2
B of this procedure for BI-1900 projects, but guidelines will vary and will be limited for smaller short-term Work Order projects of lesser scope and complexity. Details are included in DFIG internal procedures. 8 Projects Inspection Division (PID) Responsibilities PID is responsible for quality monitoring for all stages of construction and precommissioning up to final acceptance, to ensure compliance with applicable standards and project specifications 8.1 Level of Involvement PID's monitoring activities and coverage will vary from project to project based on the type of contract, project scope and complexity, geographical locations, Contractor experience, PID's level of involvement may also vary based on the effectiveness of the Contractor's Quality System. 8.2 Guidelines for PID Coverage For detailed guidelines on how PID perform their disciplined inspections, refer to Appendix A, Appendix B, and for detailed PID checklists, see the ID intranet web page under PID division. 8.3 Unsatisfactory Contractor QC Performance If the contractor does not adhere to the quality requirements, PID may be required to provide additional inspection support as outlined in Schedule Q. 8.4 Planning PID will maintain a look-ahead schedule of proposed Expenditure Requests in order to facilitate the planning for inspection manpower, office, and accommodation requirements. This will also enable PID to anticipate SAPMT's future needs in the development of Project Quality Plans and Attachment VI of Schedule Q. 8.5 Design Reviews PID coverage begins with the engineering reviews of the project proposal and detailed design per SAEP-14 and SAEP-303. 8.6 Construction Phase Start-up PID shall assign representatives to coordinate inspection activities and to attend pre-construction meetings (kick-off meetings) to highlight the main issues such
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as, but not limited to, the following: 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 Introduction of Saudi Aramco Inspection Team Members. Contractor Quality System requirements. The use and issuance of RFIs. The placement and use of Inspection Logbooks. The submittal of special process procedures (as referenced in Schedule Q). The contractor's plan for third party civil testing laboratories, Weld test Centers, RV Calibrators, NDT testing agencies, and ready mix concrete/asphalt suppliers. The submittal of proposed concrete/asphalt mix designs as per SAEP-1152. The need for conducting surveys of concrete/asphalt suppliers that are not included in the Saudi Aramco approved list. Note: Survey forms are available from ID - Batch Plant Inspection Group.
8.6.7 8.6.8
8.7
Weekly Project Progress and QC Meetings It is essential that PID representative(s), as determined by the responsible Field Supervisor, attend the weekly site meetings unless they are attending regularly scheduled QC Coordination meetings. PID's primary concern during these meetings is related to the look-ahead schedules and quality related matters. PID representatives should provide quality management support to SAPMT when meeting with the Contractor. Any disagreements with SAPMT should be communicated with them in private.
8.8
Weekly Look-ahead Schedule PID personnel should review the Contractor's look-ahead schedule to assist in the planning of coverage of the work activities. Emphasis should be placed on the start of new activities in order to prevent construction problems, and on the receipt of major equipment for early detection of potential deficiencies.
8.9
Request for Inspection (RFI) PID shall receive RFIs for all Hold and Witness Points as identified in the Contractor's approved ITPs. Immediately upon receipt, the PID representative shall sign and date the RFI and return the signed copies to the Contractor and
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SAPMT. For specific projects situations, PID, SAPMT, and the Contractor should agree on a suitable method of handling RFIs, i.e.: When faxed. 8.9.1 Function of RFI Form The RFI form is used to notify PID that an inspection point is ready for PID inspection by the Contractor's QC personnel and normally verified by SAPMT prior to PID inspection. The form is not to be used as an inspection point approval or disapproval. Any comments regarding acceptance or rejection of work, shall be reported as described in Section 9, "Inspection Department Reporting Responsibilities". 8.9.2 RFI Timing RFIs should be prepared and submitted to PID sufficiently in advance of the commencement of the work activity. Unless agreed between SAPMT and PID, RFIs should be submitted in accordance with the following time constraints: 8.9.2.1 Weekdays and Weekends/Holidays At least 24 hours for weekdays or 48 hours for weekends/ holidays prior to the time required for inspection. 8.9.2.2 Remote Areas For remote areas, RFIs should be submitted at least 48 hours in advance. However, when air travel is necessary, a minimum of 7-days notification should be provided. 8.9.2.3 Supply of Blank RFI Forms SAPMT is responsible to obtain blank RFI forms (SA 6717ENG), or a PID accepted alternative for use on their projects. 8.10 Surveillance Inspection (Without RFIs) PID has the authority to monitor on going construction activities even if an RFI was not received. The level of inspection coverage shall be in direct relation to the effectiveness of the Contractor's quality system and his ability to provide acceptable quality. 8.11 Support to SAPMT PID will assist SAPMT in enforcing and interpreting Company standards and specifications. PID should recommend solutions to construction problems/
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violations and if possible consult with the assigned Specialist in the Engineering Services Organization. 8.12 Mobilization of NDT Subcontractors At the beginning of each new project where NDT is required, PID will provide OID with the name and the date of mobilization for the NDT Sub-Contractor(s). See paragraph 7.1. Additionally, PID in support of SAPMT, will liaise with the NDT Unit to ensure that all sub-contracted NDT personnel and their procedures have received approval before starting any work on the project. 8.13 Cranes, Elevators, and Lifting Equipment PID shall ensure that all lifting equipment installed is inspected by the crane inspection group of OID prior to signing MCC. 8.14 Contractor Quality Control System 8.14.1 Contractor's Quality Plan (QP) PID will review, comment on, and approve or disapprove the Contractor's construction and pre-commissioning phase Quality Plan, including the Inspection and Test Plan (ITP), prior to the start of any construction or pre-commissioning activity, in accordance with Schedule Q. The Contractor's QP and its associated QCPs and ITPs must be recognized as dynamic documents subject to subsequent revisions as deemed necessary based on the effectiveness of the Contractor's implementation of quality requirements. Some commonly used inspection points are listed in Appendix B. PID shall have further responsibility to review the Contractor's quality control documents and test results for conformance to project requirements. 8.14.2 Contractor's Quality System Audits 8.14.2.1 Schedule At the start of the project, PID will review the Contractor's Internal Auditor qualifications and audit history, and the Quality System Audit Schedule for compliance with Schedule Q. 8.14.2.2 Checklists In advance of the scheduled audits, PID should request a
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written notification from SAPMT indicating the date, time, and location of the audit. The submittal should also include the proposed checklist as required by Schedule Q. 8.14.2.3 Monitoring of Audits PID's representative should attend as an observer both the Contractor's Internal Quality Audit and the closing meeting. PID should receive the final audit report and follow-up on critical issues. 8.14.3 ID Quality System Assessments The PQM will coordinate with the Inspection Assessment Group (IAG) in developing a schedule of assessments to be performed on Contractor Quality Systems during the project. A PID representative should participate in assessments for the construction and pre-commissioning phases, and attend the opening and closing meetings as an observer and provide assistance as required. PID should follow-up on Corrective Action Requests (CARs) generated by these assessments. 8.14.4 Assessment by PID PID should perform regular informal assessments of selected elements/processes of the Contractor Quality System. 8.14.5 Contractor QC Personnel Prior to the start of construction, PID shall follow-up with SAPMT to ensure that the Contractor's proposed QC organization chart and manning levels as required by Schedule Q, are submitted to PID for review and concurrence. PID has the authority to interview Contractor's proposed QC and NDT candidates and may also disqualify any individual or agency on technical grounds or unsatisfactory performance. 8.14.6 Quality Training and Awareness PID should monitor the Contractor training program to ensure that all Contractor and Sub-Contractor personnel are familiar with the project quality requirements for their area of responsibility. Prior to the start of each new construction activity, PID should verify that the contractor is providing ongoing training in the applicable QCPs, ITPs, and applicable standards and specifications to the assigned QC inspectors.
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8.15
Short Form Contracts PID representatives will ensure that all Contractors working under a short form contract, develop and comply with a quality control/quality assurance program. At his discretion, the PQM/Sr. Supervisor may approve QCPs/ITPs for the work activity to be performed in lieu of a quality plan. Contractor QC personnel shall be sufficiently experienced and qualified to perform inspection of the work performed.
8.16
Materials/Equipment 8.16.1 QC Procedure for Material Control PID must ensure that Contractors QC Procedures and associated ITPs for material Receiving, Storage, Traceability, and Preservation are approved prior to the start of material receiving activities. PID should verify that the ITPs identify PID witness points for all critical material, and for the first shipment from each Vendor of bulk materials. PID should check that the Contractor addresses the need for tracking material with previously known deficiencies/exception items from arrival at site through to the completion of the required corrective action. 8.16.2 Material Receiving Look-ahead schedule PID should ensure that the Contractor's weekly inspection schedule covers material receiving/inspection activities. 8.16.3 Receiving Inspections PID should be involved in receiving inspection of both Contractor and Saudi Aramco supplied materials upon arrival on site. PID should inspect major equipment (e.g., fired and unfired vessels, skid mounted equipment, pumps, compressors, etc.), and perform random inspections of bulk construction material for compliance with standards, codes and specifications, and for possible damage during shipping, handling, and installation. PID should check for the availability of the Supplier/Contractor inspection release, inspection records, and recommendations for storage and preservation at time of receipt. PID will ensure that the Contractor has a procedure for the handling, storage, and preservation of material, written in accordance with the requirements of Schedule Q. EDRs and NCRs shall be initiated in accordance with paragraphs 8.16.4 and 9.4.
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8.16.4
Material/Equipment Deficiency Reporting NCRs shall be generated and forwarded to the SAPMT Sr. Project Engineer for issuance to the Contractor for deficiencies on Contractor supplied material/equipment if he fails to issue his own internal NCR. In addition, Equipment Deficiency Reports (EDRs), per 00-SAIP-12 shall be generated and forwarded to VID for investigation by VID on either Contractor or Saudi Aramco supplied materials. (Note: The EDR will trigger a review by VID of the quality system of the Vendor, and the performance of the third party inspection agency who conducted release inspections on behalf of Saudi Aramco to prevent recurrence).
Commentary Note: EDRs should be issued where investigation of the Vendor's quality system and/or the performance the Saudi Aramco assigned Inspection Agency is required. Issuance should not be undertaken for minor instances of material or equipment deficiencies.
8.17
Batch Plants and Civil Testing Labs 8.17.1 The Batch Plant and Civil Testing Group (BP&CTG) of PID is responsible for the evaluation, approval, and monitoring of concrete/asphalt batch plants, pre-cast concrete plants, and civil materials testing laboratories in accordance with SAEP-1152. Each PID inspection office is responsible to perform the day-to-day monitoring of batching and pre-cast plants in their area, and to submit a monthly monitoring report for each batch plant to BP&CTG. If concerns are detected affecting a specific project, the responsible SAPMT shall be informed.
Commentary Note: While not a PID function, PID Supervisors should encourage SAPMT and Contractor's to develop multiple suppliers in an area where possible to ensure adequate competition resulting in an end product of the highest possible quality.
8.17.2
Initial Vendor/Plant survey report should be prepared and submitted to PID sufficiently in advance of utilizing independent civil testing laboratories and/or asphalt ready mixed concrete plants. The survey report shall be submitted only to the relevant PID section when it is verified by the Contractor that the proposed companies meet the minimum requirements of the applicable specifications. Even if the
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proposed service providers or suppliers are listed as Saudi Aramco approved local manufacturers, an initial vendor survey is still required. 8.18 Pre-commissioning Activities The PQM will coordinate PID's involvement in Pre-commissioning activities with the PM Representative to ensure that all facility exception items have been identified and resolved. 8.19 Records PID shall ensure production of the construction quality records of the project are maintained and are available at the work site. SAPMT is responsible for: a) b) Preparing the original and revised Project Records in accordance with the Drafting Manual and SAEP-122. Furnishing to the Proponent copies of essential information, quality-related documents, vessel inspections, and pertinent project information that will assist operations in the future.
8.20
Mechanical Completion Certificate (MCC) 8.20.1 General Final completion of the project shall be in accordance with GI-0002.710. The authorized PID representative shall sign the MCC after verification that the project has met the requirements of project documents, Company standards and procedures, and applicable National and International codes. 8.20.2 Pre-MCC Requirements PID shall perform a final Inspection of the facility and record outstanding items on the Exception Item List, SA 6133 or a suitable alternative as determined by the acceptance committee. In addition, PID will ensure that all open logbook entries, NCRs, and Worksheets are resolved or included on the exception item List. Items required for start-up or impacting safety are to be marked as "Yes" Items. All other items are designated as "No" Items. Only after all "Yes" Items are cleared, may the Mechanical Completion Certificate be signed. If records books as required by SAEP-122, or project "As built" drawings have not been provided by the time of facility walkthrough, and item shall be added to the EIL, and marked as a "No" item. For electrical systems energization, see Appendix A, Paragraph A.18.
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8.20.3
Post-MCC Requirements PID involvement in the project construction phase usually ends with the signing of the MCC. After signature of the MCC, the Proponent is responsible for signing off completed exception items or making arrangements for the originator to be available for sign-off. At their discretion, and based on workload and priorities, PID may continue involvement in the project to clear their exception items when requested by the Proponent. PID should request from the Proponent, a specific charge number for this work.
Inspection Department Reporting Responsibilities 9.1 Comments Submittal ID's comments and recommendations concerning the project shall be submitted to SAPMT or their designated representative for implementation of corrective action. Prior to the start-up of construction, comments/violations noted during reviews by ID on project designs and procurement should be covered within letters/memos, E-mail, E-Reviews, or forms addressed to the Project Manager or Engineer. 9.2 Violation Reporting Requirements 9.2.1 Methods of Reporting to SAPMT Inspection will report violations to SAPMT by one or more of the methods listed in this section. The method of notification can be in any sequence deemed appropriate based on the urgency and severity of the violation. 9.2.2 Violation Reporting Criteria Inspectors shall denote the appropriate specification violated with regard to the cut-off dates as found in SAEP-14 (e.g., Project Proposal approval date). Logbook entries shall note the specific standard and paragraph violated, and shall include sufficient information for SAPMT to correct the deficiencies. Where applicable, logbook entries should identify the equipment number and location. 9.3 Inspection Log Book On construction sites, the inspection logbook is the initial method of communication with SAPMT (communicating violations verbally with SAPMT
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should precede the logbook entry if practical). The inspection logbook is utilized to record: a. b. c. 9.3.1 Violations observed against the requirements of project documents, Company standards and procedures, or applicable codes. Inspection observations and comments. Job clarification, recommendations, or any information deemed necessary, such as the specific location of the violations on the jobsite. Inspection Logbooks on Major Projects Upon commencement of a large, complex project, ID shall place at least two (2) or more logbooks at the job site: a) One logbook shall be identified as "Violation and Action Item Logbook" and shall be placed in the SAPMT field office at site. All logbook entries shall be limited to standard/code/ specification/drawing, etc., violations and/or other items that require action by SAPMT. The second logbook should be identified as "RFI and Surveillance Activities Logbook" and shall be located in the Inspection office at the job site. This logbook should be utilized to record any information deemed necessary by the inspector such as, daily communications, acceptance of an inspection task, or other related observations which may not require a response on the part of SAPMT but which is related to the project. Alternatively, other effective systems of communication, as agreed between SAPMT and PID may be used to provide daily communication and demonstrate adequate Project Inspection coverage of the work.
b)
On projects with full time involvement of more than one inspection discipline, separate Inspection Logbooks can be provided for each discipline (i.e., mechanical, civil, electrical, etc.). 9.3.2 Inspection Logbook on Smaller Projects For smaller less complex projects, it is still required that both Logbooks be used however, PID has the option to combine the Violation and Action Item Logbook and the RFI and Surveillance Activities Logbook into a single logbook entitled "Inspection Logbook", and shall then locate it in the SAPMT field office at the job-site. The single logbook may also include entries for all inspection disciplines.
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9.3.3
Logbook Entry Format A standardized entry format shall be used in all logbooks as shown in Appendix C. Elements shall include the following: Violation and Action Item Logbook a) b) c) d) e) The sequential number of each log book entry. Date and type of inspection (i.e., mechanical, civil, etc.). Inspector's observations, recommendations, and name (printed clearly). Date of Site Representative's reply. (Normally expected within 3 working days). SAPMT Representative's reply, initials, and name (printed clearly).
Commentary Note: On major projects, and as agreed between PID and SAPMT, SAPMT may delegate this responsibility to the Contractor's QC Manager. In this case, SAPMT's representative must review and initial the response to indicate agreement.
g) h)
Date of inspection of corrective action. Inspector's initials of acceptance of corrective action.
RFI and Surveillance Activities Logbook a) b) c) d) e) f) 9.3.4 Each page of the logbook shall have a unique sequential number. Date and reference to Inspection discipline. Number of RFI (if applicable). Indication of whether the work activity was accepted. Any comments or observations by the PID representative. PID representatives name and signature.
Logbook Retention Logbooks are the property of the Inspection Department. At the end of the project the inspector is required to collect the logbook from the jobsite and place it in the project file at the responsible Inspection office. Logbooks for hydrocarbon projects should be retained for a period of no less than two years after facility commissioning.
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9.3.5
Electronic Logbooks The use of an electronic form of project logbook is acceptable and PID Sections are encouraged to develop and implement such a system. The logbook should follow the same general format as stated above, and be accessible by all members of the project team.
9.4
Non-Conformance Report (NCR) 9.4.1 General NCRs shall be generated and forwarded to the SAPMT representative (normally the Sr. Project Engineer) for issuance to the contractor for violations to Saudi Aramco system of standards, project specifications, and the approved quality plan during any project phase. Prior to initiating NCRs, the ID representative (VID/PID) shall discuss the situation with SAPMT, providing sufficient information to enable them to understand the deficiency along with the necessary supporting documents. The ID representative (VID/PID) shall verify that corrective action has been completed, and is acceptable, prior to NCR closure. During procurement, all standards and quality plan violations should be reported via the issuance of an NCR to enable accurate analysis of performance. 9.4.2 Situations Prompting NCR Issuance Depending on the specific situation, it may be necessary for an NCR to be generated without any previous logbook notification to SAPMT. An NCR should be issued in the following situations: a) If the Contractor has purchased or placed an order for equipment or material that is not in compliance with Saudi Aramco Standards. If any part of the Project Specifications (not Saudi Aramco mandatory standards) has been violated, and concurrence for the deviation has not been obtained from the Proponent. If the Contractor is found in non-compliance with Schedule Q or to his approved Quality Plan (QP). If Contractor supplied material or equipment is shipped to site without inspection. When such material is shipped with known violations to Mandatory Saudi Aramco Engineering Requirements without first obtaining Saudi Aramco approval.
b)
c) d)
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e)
When documented work was not in compliance with the applicable standards or specifications. The NCR should be generated when no timely response (Reference Section 9.4) is given to a logbook entry, or when the response is not satisfactory to Inspection.
9.4.3
Scope of NCRs A separate NCR should be generated and issued for each violation, unless the violations are related to a single equipment or construction item and sharing the same corrective action. The NCR must require the Contractor to investigate the root cause of the violation and the proposed action to prevent recurrence. (Violations discovered by PID and not detected by the Contractor, indicates a weakness of the Contractor's Quality Control System).
9.4.4
Elevating NCRs to Worksheets If a valid NCR has been rejected by SAPMT, the PQM / PID Sr. Supervisor should contact the SAPMT Project Manager to discuss the concern and to evaluate the need for worksheet issuance in accordance with GI-0400.001. The worksheet however, could be issued without further discussion if the situation warrants it.
9.5
Equipment Deficiency Report (EDR) Equipment Deficiency Reports (EDRs), per 00-SAIP-12, shall be generated and forwarded to VID for investigation by VID on either Contractor or Saudi Aramco supplied materials. (Note: The EDR will trigger a review by VID of the quality system of the Vendor, and the performance of the third party inspection agency who conducted release inspections on behalf of Saudi Aramco to prevent recurrence). The cost and schedule impact of an EDR should be determined jointly by SAPMT and ID prior to its closure.
Commentary Note: EDRs should be issued where investigation of the Vendor's quality system and/or the performance of the Saudi Aramco assigned Inspection Agency is required. Issuance should not be undertaken for minor instances of material or equipment deficiencies.
9.6
Worksheet 9.6.1 Worksheet Issuance When decided by PQM/Sr. Supervisor Worksheets will be generated when a valid NCR is not issued to the contractor by SAPMT within
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two working days. The worksheet is utilized to inform SAPMT, the Proponent, and other Interested Parties that design, procurement, or construction does not conform to project documents, Company standards and procedures, or applicable International codes. 9.6.2 Worksheet Target Recipients Worksheets must be approved by the PID Sr. Supervisor. Worksheets are normally addressed to the Project Manager and have a wide management distribution that may include the Department Managers of SAPMT, Proponent, ID, and other interested parties. 9.7 Project Quality Index (PQI) The PQM or his representative(s) shall calculate a monthly PQI jointly with SAPMT and Contractor representatives. The PQI is a measure of contractor compliance to project quality requirements and the approved quality plan per the forms shown in Appendix D. 10 Deviations to Company Requirements 10.1 Precedence of Contract Documents Each project contract shall denote applicable document precedence and Standard cut-off date to be used to determine inspection criteria. Generally Saudi Aramco Standards, mandatory Standard Drawings, and Company adopted National or International Codes and Standards, take precedence over the construction drawings, project specifications, and the scope of work. A waiver is required to deviate from Saudi Aramco Standards even when the proponent agrees with the deviation. Refer to SAEP-302 for details. 10.2 Waiver of Inspection Requirements Waiver of Inspection requirements as opposed to an Engineering Standard or specification requirements (as identified in quality plans or SA-175s) for Contractor's inspection, testing or examination during the various work phases, may be waived only with SAIR written approval in coordination with the PQM. Waiver of Contractor requirements to perform inspections on SA-175s are further covered in SAER-1972. 10.3 Standards Interpretation For disagreements in the interpretation of Saudi Aramco Engineering Standards, a written concurrence from the appropriate CSD Engineer is recommended.
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1 July 2008
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with no other changes.
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Appendix A Instructions for PID Coverage A.1 Start of PID Coverage PID coverage begins with the engineering review of the project proposal and detailed design per SAEP-303. This provides Inspection with the opportunity to provide timely input to the project. A.2 Assistance to SAPMT PID will assist SAPMT in enforcing, recommending, and interpreting Company standards and specifications. This may require coordination or consultation with the assigned Specialist in the Engineering Services Organization. A.3 Material Analysis A.3.1 Concrete Mix Design Verification At least thirty days prior to the start of the applicable work, the concrete mix design shall be submitted for review and approval in accordance with the requirements of Schedule Q. PID shall review and approve the mix design as per the requirements of SAEP-1152. A.3.2 Bituminous Asphalt Concrete verification Prior to inspection of asphalt concrete paving, PID shall review the material analysis of the asphalt concrete and its constituent parts (i.e., aggregate), and should also verify that the asphalt concrete mix design has been reviewed and approved by Saudi Aramco. A.3.3 Soil and Soil Compaction Verification Prior to inspection of compacted fill or embankment, PID will review fill/ backfill material analysis reports from an independent laboratory, approved by Saudi Aramco, such as soil type, Proctor Density test results, optimum moisture content, etc., in order to verify optimum density values used to achieve compaction test results. A.4 Site Development Site work and ancillary site material installation will be monitored by Inspection. PID may review material laboratory reports, inspect the laying down of fill, and monitor compaction tests. Utility piping and sewer systems will be inspected to ensure installation and testing are performed according to specifications.
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A.5
Excavation, Ditching and Backfill Excavations will be inspected to ensure compliance with Safety Standards and that materials placed meet Saudi Aramco specifications. Inspection will include the review of soil laboratory test reports (see A.3.3) and monitoring of compaction tests.
A.6
Pile Driving PID will review the pile-driving procedure including the equipment to be used to drive piles. Pile-driving activities will be monitored and all splice-welds will be inspected as required by the specification. For onshore applications, the inspector will check the protective coating on the pile as specified in the project specifications. PID will review SAPMT's pilediving records (including the geotechnical report, results of test pile, required blow count, and tip elevations).
A.7
Cement Concrete and Asphalt Concrete Construction A.7.1 Concrete, Masonry, and Grout A.7.1.1 Ready-Mix Concrete Monitoring PID will verify that suppliers of Portland cement concrete are Saudi Aramco approved. PID will review and approve the concrete mix design by verifying that the mix design is in compliance with Project specifications. In addition, PID will monitor the production of Portland cement ready-mix concrete, and verify the test results for the raw materials. PID will verify the Exposure Type of the project site, based on the in-situ soils and groundwater analysis, against the requirements of SAES-Q-001, Table 1. A.7.1.2 Pre-Pour Inspection PID will check grade preparation, formwork, installation of embedded items, reinforcements, cleanliness, depths, sizes, chamfer strips, elevations, and joints prior to concrete placement. Handling and fabrication of epoxy-coated rebar will be monitored to ensure that damaged coating is repaired prior to concrete placement.
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A.7.1.3
Pouring & Post-Pouring Inspections PID will witness most concrete pours and monitor concrete temperatures, slump tests, placement, vibration, preparation of concrete for test-cylinders, and finishing. After concrete placement, PID will monitor the curing process (including the quality of water used), form removal, re-shoring, and surface finish of the exposed concrete. The PID inspector will inform SAPMT immediately of any problems encountered during concrete placement for prompt corrective action.
A.7.1.4
Masonry Work Monitoring PID will monitor the masonry installation to verify that embedded items, masonry units, and finishing are properly installed according to the drawings and specifications. PID will review laboratory reports for masonry materials to verify that the correct materials are used and the strength is in accordance with the applicable specification.
A.7.1.5
Grouting Work Inspection PID will inspect all surface preparation prior to grouting and will monitor both the grouting process and curing.
A.7.1.6
Concrete Pouring Plan A concrete pour plan will be submitted to PID for review and approval for major pours such as critical foundations, slabs, girders, structural walls, anchor blocks, etc. At minimum, the plan will include an assessment of the personnel, equipment, weather, distance to the concrete batch plant, number of mix trucks, site access, and possible problem areas (i.e., cold joints).
A.7.2
Asphalt and Road Construction A.7.2.1 Sub-grade Suitability PID will check the suitability of the existing sub-grade prior to any activities in road construction. If the existing subgrade is not suitable, proper corrective action must be taken in accordance with SAES-Q-006 requirements.
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A.7.2.2
Base/Sub-Base Suitability PID will verify that the gradation and physical properties of the base and sub-base meet the project's specification requirements. Such data should be based on tests made by an independent laboratory approved by Saudi Aramco. PID will check the quality of the placement and finishing of each layer of the sub-base and aggregate base course, and will verify elevations and the results of the required tests, before proceeding to the next layer.
A.7.2.3
Bituminous Prime/Tack Coats and Asphalt Paving PID will check the application methods and rates of the prime and tack coats. PID will monitor asphalt concrete temperature on arrival, protection of asphalt mix in transit, its placement, its depths, and its methods of rolling and surface finishing.
A.7.2.4
Checking Asphalt Pavement PID will check the testing of compacted and un-compacted asphalt concrete, the level of smoothness of finished surfaces and the elevation conformance in accordance with SAES-Q-006 requirements.
A.8
Building, Framing, and Finishing PID will monitor internal and external craftwork for correct use of materials and installations according to project requirements, and relevant Saudi Aramco Standards and Specifications. Framing will be monitored to ensure that materials are the size, shape, quality, and type specified. All cabinets, internal walls, doors, jambs, floor tiles, windows, and all finishes will be monitored for acceptable quality. PID will verify and witness tests as required on all concealed installations prior to covering.
A.9
Structural Steel PID will verify that structural steel works comply with project requirements for strength, dimensional tolerance, and methods of fabrication/installation. Tightening of bolts will randomly be inspected for compliance with the bolting specifications. Welding, NDT, and coating will be monitored for conformance to project documents, Company standards and procedures, and applicable codes.
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A.10
Welding A.10.1 Welding/Brazing Procedures PID will review Contractor's welding and brazing procedures and approve their use for a particular project after technical approval of each procedure has been obtained from the Welding Group of CSD. A.10.2 Socket Weld Gap and Thread Engagement Control In accordance with Schedule Q, Attachment IV, PID shall verify that the Contractor has developed special process procedures for the control of gap width for socket weld connections, and thread engagement for threaded connections. At the discretion of PID, random NDT (RT) may be performed at a minimum rate of 10% on these connections, to verify that the requirements of these procedures have been met. A.10.3 Welder, Welding Operator, and/or Brazer Certification A.10.3.1 Welding Workforce Qualifications PID will review the qualification documentation for all welders, welding operators, and brazers to ensure personnel are qualified in accordance with the requirements of applicable codes, the applicable SAES 'W' series Standard (e.g., SAES-W-010, 011, 012, 013), and SAEP-324. PID will verify that only Saudi Aramco-approved Testing Agencies (or Contractors and Fabricators approved to do so per SAEP-324) perform welder performance qualification tests. The test records for all welders, welding operators, and brazers shall be available at all times at the work location for review by PID. A.10.3.2 Job Clearance Cards (JCC) PID will issue JCC's prior to the start of work to all certified and registered welders, welding operators, and/or brazers. The JCC shall be kept in their possession at all times. A.10.4 Welding Inspection Inspection Items and Weld Traceability: PID will monitor and randomly examine materials to be welded, welding consumables, joint preparation, fit-up, welding processes, equipment, and completed welds for conformance to Company Standards and Procedures, and applicable International codes. PID will ensure that weld traceability is
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maintained for the duration of the project. Weld traceability will consist of, but not limited to, the following; weld maps, weld numbers, NDT status/report No., repair standing (if required), and welder's identification. A.10.5 Repair Rates and Welder Performance SAES-W series standards require that the Contractor review and track project and Welder repair rates daily. PID will monitor and evaluate production weld repair rates and welder performance weekly. The target for maximum project repair rate (calculated on a joint basis) should normally not exceed 5%. The repair rate for welders (calculated on a linear basis) must not exceed 5% weekly. PID's Authority Regarding Poor Performance: PID reserves the authority to revoke a JCC, or require retesting of any welder, welding operator, and/or brazer at any time due to unsatisfactory performance. A.10.6 Post-Weld Heat Treatment PID will monitor the postweld heat treatment of critical piping and vessels on Saudi Aramco construction projects to ensure compliance with project specifications and applicable industry codes/standards. A.10.7 NDT in Lieu of Hydrostatic Testing A waiver as defined in SAES-A-004 must be obtained to allow NDT in lieu of hydrostatic testing. Detailed inspections of all such joints must be performed by PID including, but not limited to, the following: a) b) The fit-up, root pass, and hot pass of each weld. Verifying that the Contractor's approved QC Inspector witnesses and records all observations made during performance of the entire weld. Ensuring that the Contractor instructs his NDT subcontractor to use a slow speed film to increase sensitivity of the resultant radiographic image. Ensuring that once welding starts, it continues without interruption until completed.
c)
d) A.11
Non-Destructive Testing (NDT) See paragraph 8.12.
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A.12
Piping and Pipelines A.12.1 Process and Utility Piping PID will randomly check piping materials and handling for conformance to the project documents and applicable standards, compliance to mill test certificates, and for physical damage. The check will include the type, grade, schedule, and rating of pipe, fittings, and appurtenances. PID will monitor fabrication, NDT, coating, and installation of piping to ensure compliance with the project requirements, applicable codes and Company standards and procedures. Prior to MCC signing, a minimum of 10% of all flanges and fittings shall be checked to ensure correct type, schedule, and rating, along with proper torquing of flanges per SAES-L-350 paragraph Appendix A. A.12.2 Underground Piping PID will monitor preparation, handling, installation, NDT, and backfilling of underground piping in accordance with the project documents and applicable Company standards and procedures. PID will randomly inspect the application of external coatings or wraps but reserves the authority to witness the 100% holiday testing of the external coating when it is required, prior to back-fill. A.12.3 Cross-country Pipelines PID will monitor the stringing, bending, welding, NDT, installation, coating, cathodic protection, insulation, and back-filling to ensure conformance to project documents and applicable Company standards and procedures. PID will also monitor fabrication and double-ending performed at IK fabrication yards. A.12.4 Pressure Testing A.12.4.1 Pre-Pressure Testing Inspection Actions Prior to pressure testing, PID will review and approve Contractor's pressure test procedure, test diagram, and lay-up procedure for conformance to SAES-A-004, SAES-A-005, SAES-A-007, and SAES-L-350 respectively. All NDT will be confirmed by PID as having been completed and accepted prior to any pressure testing. PID shall perform a pre-test punch listing of the system to be tested prior to hydrostatic testing to ensure that all attachments to the piping are
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complete. The Contractor shall provide a test analysis for water purity and chloride content when pressure testing stainless steel components. Test diagrams and procedures will describe the limits of piping and equipment, test pressures, test temperature, test fluid, line flushing, and safety precautions, as well as the requirements for venting during water filling and de-pressurization. Test diagrams will clearly indicate the limiting factor for each test, i.e., wall thickness, flange rating, Code, etc. A.12.4.2 Pressure Testing Witness Responsibility Pressure tests will be witnessed, inspected, and accepted by ID personnel. This responsibility may be formally delegated by PID to other Saudi Aramco representatives. A.12.4.3 Post-Pressure Testing Inspection Actions After all successful pressure tests, a Pressure Test Report (Form SA 2642) will be completed and become part of the documentation package. All SA 2642 forms will become a part of the Project Inspection Records per SAEP-122. PID will monitor the lay-up of piping and equipment A.13 Mechanical Equipment A.13.1 Equipment Inspections & Final Closures Equipment will be inspected for vendor/equipment deficiencies, specification violations, and for possible damage from shipping or during installation. A review of the Vendor supplied inspection reports and the SA-175 requirements will be performed. PID will conduct internal inspections on drums, vessels, and other equipment prior to final closure. PID will sign the final closure certificate along with other responsible agencies prior to final closure of the equipment. For vessel closures, any non-conformance noted regarding gasket rating/installation will delay closure certificate sign-off until such time as the non-conformity is corrected. PID is to use form SA 2093 (Equipment Inspection Record - General) to document its findings of the internal inspections, as well as final external inspections, hydrotests, etc. The signed form SA 2093 will be made part of the final Project Inspection Records per SAEP-122. A.13.2 Inspection of rotating equipment shall be limited only to installation and assembly on the foundation, skid alignment, and plumbness.
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Witness of shaft and coupling alignment and piping flange connection shall be the responsibility of the Proponent's rotating engineers. A.13.3 Equipment Documents and Report Reviews Safety Instruction Sheets (SIS), Manufacturer's Data Sheets, as well as NDT completion, must be reviewed before equipment is pressure tested as required by SAES-A-004. A.14 Gaskets A.14.1 Gaskets Inspection Criteria Correct gasket type, rating, and installation will be verified. A minimum 10% random inspection will be done by Saudi Aramco Project Inspection prior to final MCC punchlisting for piping and equipment systems. A.14.2 Delayed Reinstatement Action If reinstatement after hydrostatic testing is delayed due to construction or commissioning constraints, a logbook entry or MCC Exception Item Listing (EIL) will be done to document temporary gasket installations for each hydrostatic test package or system involved. A.14.3 Flange Bolt Torquing PID shall randomly monitor all flange bolt torquing to ensure that the Contractor is using properly calibrating equipment, correct tightening sequence, and required torque values as described in his approved QCP/ITP. A.15 Relief Valves Procedures for testing and installation of relief valves are described in SAEP318, 319, 1131 and SAES-J-600. Prior to obtaining the relief valve computer number, PID or the Proponent's Inspection Supervisor will review and sign for the validity of data entered on the Relief Valve Authorization form (3099-AENG) against the P&ID and calculation sheets. PID will inspect the installation of the relief valve, and sign the verification portion of Form (3099-A-ENG). Assignment of identifying numbers and entry of the approved Form (3099-AENG) will be arranged through the Relief Valve Administrator of OID.
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A.16
Paints and Coatings A.16.1 Monitoring & Testing PID should monitor the application and testing of protective coatings to ensure compliance with project documents, Company standards and procedures, and applicable codes. Coating inspection will include surface preparation, coating application, dry film thickness measurement, and weather conditions. Holiday testing of internal vessel coatings and external coating of pipelines prior to covering will be witnessed by PID. A.16.2 Personnel Qualifications PID will verify that all contractor personnel associated with the preparation, application, or direct supervision of protective coatings are qualified and certified per SAEP-316 by a Saudi Aramco certified Level II Coating Inspector. PID will also verify that all contractor personnel associated with the inspection of protective coatings are qualified and certified in accordance with Schedule Q.
A.17
Cathodic Protection (CP) Monitoring Activities PID will monitor the installation of cathodic protection for tanks, pipelines, offshore structures, and plant applications. This will include the witness of drill stem resistance measurement tests, holiday testing of Anode cables, a check for proper anodes/anode beds, correct number of test and bonding stations, insulation flanges and spools, and associated equipment or materials. PID will also check for correct system polarity, continuity of test station conductors, and the timely application of temporary CP on newly constructed facilities. PID will verify that construction drawings have been reviewed and approved by the SAES-X series of standards.
A.18
Electrical For electrical conductors and equipment, PID will monitor tests for groundresistance measurements, cable insulation, and equipment testing. All installations that are intended to be concealed will be monitored prior to backfill or covering. Construction and installation methods will be monitored to ensure that no damage is done to materials or equipment. PID will check that all medium and high voltage cable splicers hold valid splicer certification cards, and will issue JCC's prior to the commencement of splicing. Prior to energization of power distribution systems, PID will verify installation is sound and safe to energize. All pre-commissioning activities performed prior to
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MCCs, will be carried out as per the responsibilities designated by the supplement table of GI-0002.710-6. A.19 Communications A.19.1 Quality Monitoring Responsibility The PID Communications Group is responsible for quality monitoring of Outside Plant (OSP) projects and Premise Distribution Systems (PDS). A.19.2 Scope of Inspections Inspections are made throughout all phases of design and construction to ensure compliance with the SAES-T standards. A.20 Cranes, Elevators, and Lifting Equipment PID shall ensure that all lifting equipment installed is inspected by the Saudi Aramco Crane Inspection Group of OID prior to signing final MCC. Also, see paragraph 7.3 for details. Testing: A.20.1 General Criteria OID/Crane Inspection Group will witness and verify Inspection and Testing as applicable in accordance with approved Project/Contract specific Quality Plan or Inspection and Test Plans. Final Acceptance of test results will be the responsibility of OID/Crane Inspection Group. A.20.2 Lifting Equipment Testing Criteria Testing of all lifting equipment will be witnessed and documented as required by OID/Crane Inspection Group. Acceptance of test results for all lifting equipment will be by OID/Crane Inspection Group. A.21 Alloy Verification Program Vendors and Contractors will have implemented an alloy verification program with documented procedures as per SAES-A-206. The alloy verification program procedures, in-process inspection, and final data package will be made available to the ID for review, verification, and acceptance prior to final release. VID will ensure that Contractors have an acceptable alloy verification program for equipment manufacturing. PID will ensure that a similar program exists for field fabrication.
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Appendix B Typical Inspection Points B.1 Protective Coatings (External and Internal) B.1.1 B.1.2 B.1.3 B.1.4 B.1.5 B.1.6 B.1.7 B.1.8 B.2 Welding B.2.1 B.2.2 B.2.3 B.2.4 B.2.5 B.2.6 B.2.7 B.2.8 B.2.9 B.3 Brazing B.3.1 B.3.2 B.3.3 B.4 Brazing procedure Brazer qualifications Certification of brazed joint at job site Welding procedure and Welder qualifications Non-destructive testing Procedures, Personnel, and activity start-up Start of fabrication and welding activities Selection of points for NDT Radiographic film interpretation by Company certified Interpreters Repair of cracked welds Stress relieving Tie-in welds Socket weld gap and thread engagement Personnel qualification Surface preparation prior to coating Paint Mixing DFT Readings Tests (Adhesion, Holiday, etc.) Prior to top coat for APCS-4 or 6 Application of heat shrink sleeves Coating repair
Post-weld Heat Treatment B.4.1 B.4.2 B.4.3 B.4.4 Approved procedure Calibration of measuring devices Documentation Hardness testing
B.5
Piping/Pipelines B.5.1 Pipe bending

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B.5.2 B.5.3 B.5.4 B.5.5 B.6
Lowering-in of pipeline sections Lay-up of piping/pipelines Road crossings Thrust boring
Plant Piping B.6.1 B.6.2 B.6.3 B.6.4 B.6.5 Flange and fitting type and rating Gasket type and installation Bolt Torquing Piping re-instatement after hydrostatic test Hot taps and stopple installation
B.7
Vessels B.7.1 B.7.2 Lay-up of vessels Vessels closure
B.8
Pressure testing B.8.1 B.8.2 B.8.3 B.8.4 B.8.5 Calibration of pressure gauges and relief valves for use in pressure testing when performed by other than approved testing agency Punchlisting prior to pressure test/review of test package Filling and venting Stabilization Pressurization
B.9
Pressure Relieving Devices B.9.1 B.9.2 Documentation verification Installation verification
B.10
Plumbing B.10.1 B.10.2 B.10.3 B.10.4 B.10.5 Sand bedding and cover Head test, sanitary lines Pressure test, water lines Test sanitary manholes Closing of walls and ceilings
B.11
HVAC B.11.1 B.11.2 Prior to installation of duct insulation Installation of HVAC units
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B.11.3 B.11.4 B.11.5 B.11.6 B.11.7 B.11.8 B.12 Civil B.12.1 B.12.2 B.12.3 B.12.4 B.12.5 B.12.6 B.12.7 B.12.8 B.12.9 B.12.10 B.12.11 B.12.12 B.12.13 B.13 Electrical B.13.1
Fire dampers & sleeves in fire rated walls Brazing and soldering of refrigeration lines Pressure test, refrigeration lines Vacuum testing of refrigeration lines Testing and balancing of HVAC system Closing of walls and ceilings
Prior to closure of formwork Prior to concrete placement, grouting, and asphalting Prior to bituminous coating of buried concrete structures Prior to asphalt roofing placement Prior to commencement of the initial bending of epoxy coated reinforcing bar Verify that a geo-technical survey has been carried out Prior to closure of walls and ceilings Bottom of excavations After preparation of the bottom of foundations Before backfilling around structures After preparing the existing sub-grade, and after each layer for road construction Sand cover of piping Concrete prior to any repair
All electrical, instrumentation, or Cathodic Protection equipment/material that will be buried, concealed behind a wall, ceiling, or floor, including but not limited to: B.13.1.1 B.13.1.2 B.13.1.3 Prior to backfilling of direct buried cable or conduit Prior to covering cable conduit within a permanent wall, ceiling, floor, or tank bottom Prior to burying a grounding connection, i.e.: thermite welding (cadweld), brazing, or approved compression connectors Prior to burying a splice on a cable rated above 1000 volts Prior to burying cathodic protection anodes and connections
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B.13.1.4 B.13.1.5
B.13.1.6 B.13.1.7 B.13.1.8 B.13.2 B.13.3 B.13.4 B.13.5 B.13.6 B.13.7
Thermite welding (cadweld) of cathodic protection cables to buried pipelines Witness of instrument calibrations Witness leak testing of process tubing
Cable splicer certification for cable rated above 1000 volts. (GI-0002.705 & SAES-P-104) Prior to wires/cables pulled into conduits or cable trays Prior to energizing a cable or piece of equipment. (GI-0002.703) Grounding and electrode earth resistance tests Installation, cable pulling, damming, and compound pouring of all conduit sealing fittings Cathodic Protection B.13.7.1 B.13.7.2 B.13.7.3 B.13.7.4 Completion of bonding station installations. Testing of impressed current anode cables (dielectric testing). Completion of station installations for pipelines. Resistance measurements for deep anode bed test anodes.
B.13.8 B.13.9 B.13.10 B.14
Testing of illumination levels Instrumentation loop checks Instrumentation calibration
Communications B.14.1 Buried Cable B.14.1.1 B.14.1.2 B.14.1.3 B.14.2 Trench before installation of the sand pad Cable during placing operation Marker tape installation
Underground conduit B.14.2.1 B.14.2.2 B.14.2.3 Trench before installation of the conduit Conduit before concrete encasement including mandrel testing Marker tape/orange dye installation
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B.14.3
Manholes B.14.3.1 B.14.3.2 B.14.3.3 B.14.3.4 Excavation for bracing/shoring when depth reaches 5' and until completion Internal form work before pouring concrete for duct terminators, inserts, etc. Grounding connections when rods are outside of manhole Ring and cover frame installation
B.14.4
Underground cable placement B.14.4.1 B.14.4.2 B.14.4.3 B.14.4.4 Reel set-up and choice of duct Tensiometer Mandrel test ducts Cable and cable pulling
B.14.5
Cable splicing B.14.5.1 B.14.5.2 B.14.5.3 Underground check cable racking in manhole Splice connectors, after 50 pairs or less, after 600 pairs or less, and after every 600 pairs on larger cables Completed splice before closing case
B.14.6
Communications work in Buildings B.14.6.1 B.14.6.2 B.14.6.3 B.14.6.4 Underground entrance conduit before concrete encasement, including mandrel testing Closet/equipment room requirements prior to and during construction Distribution system design before start of installation Before closing of walls/ceilings which will hide communications pathways
B1.14.7
Cable testing B.14.7.1 Check test set-up before start of tests
B.15
Cranes B.15.1 Fixed cranes, elevators, Escalators, Powered platforms/Suspended Scaffolds, Storage/Retrieval Machines
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B.15.1.1 B.15.1.2
Factory operational and any required proof load tests conducted and witnessed by V.I.D Test certificates showing conformance of all material and assemblies to the specified codes and standards, including pre-delivery inspection and test results Clearly marked capacity in Arabic and English in metric units of measurement Valid Saudi Aramco Crane Safety Inspection Sticker All initial inspection and load tests following installation of the equipment All reinstalled, altered, modified, or extensively repaired cranes and lifting equipment Inspection and load tests, and periodic load tests as required by the relevant standard, shall be witnessed by Saudi Aramco Crane Inspection Group
B.15.1.3 B.15.1.4 B.15.1.5 B.15.1.6 B.15.1.7
B.15.2
Mobile cranes, and Side-boom Tractors B.15.2.1 B.15.2.2 Valid Saudi Aramco Crane Safety Inspection Sticker A crane or side-boom tractor in which the load sustaining parts have been altered, replaced, or repaired shall require a witnessed load test and re-inspection by Saudi Aramco Crane Inspection Group Any crane which has undergone a boom modification or re-configuration shall require re-inspection by Saudi Aramco Crane Inspection Group
B.15.2.3
B.15.3
Vehicle mounted elevating and rotating aerial devices, articulating boom cranes B.15.3.1 The required results of any periodic dielectric and acoustic emission certification shall be made available to Saudi Aramco Crane Inspection Group for review prior to performing the requested periodic mechanical inspection.
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Appendix C Logbook Format

INSPECTION DEPT. SIGN OFF & DATE
INSPECTION DEPARTMENT Entry No. 1
SAPMT
Date
MM/DD/YY
DATE Civil Steel plates and the bars used in the pipe support foundations were neither galvanized nor coated with zinc rich epoxy primer (APCS-1C of SAES-H-101). This violates SAES-Q-001, Section 6.4. (Full name) B. Al-Basher
MM/DD/YY
REPLY The contactor was instructed to comply with the Standard requirement, and the required coating with zinc rich epoxy is in progress
Completed MM/DD/YY
(Full name) D.D. Barry
B. Al-Basher
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Appendix D (PQI Format - Procurement Phase)
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Appendix D (PQI Format - Construction Phase)
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Appendix D (PQI Format - Summary Sheet)
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Engineering Procedure

Saudi Aramco DeskTop Standards

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1141 SAEP-1142 SAEP-1152

GI-0002.705 GI-0002.710 GI-0150.003 GI-0400.001

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

Project Proposal Development

Bid Explanation Meeting

Technical Bid Evaluation

Design & Procurement Kick-Off Meeting

Construction Kick-off Meeting

VID OID PID IAG PQM

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

5.4 5.5 5.6 5.7

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

Date of inspection of corrective action. Inspector's initials of acceptance of corrective action.

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

Non-Destructive Testing (NDT) See paragraph 8.12.

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

SAEP-1150 Inspection Coverage on Projects

Piping/Pipelines B.5.1 Pipe bending

SAEP-1150 Inspection Coverage on Projects

B.5.2 B.5.3 B.5.4 B.5.5 B.6

Lowering-in of pipeline sections Lay-up of piping/pipelines Road crossings Thrust boring

Vessels B.7.1 B.7.2 Lay-up of vessels Vessels closure

Pressure Relieving Devices B.9.1 B.9.2 Documentation verification Installation verification