SAEP-1150

Previous Issue: 1 July 2008 Next Planned Update: 1 July 2013 Revised paragraphs are indicated in the right margin Page 1 of 50 Primary contact: Kakpovbia, Anthony Eyankwiere on 966-3-8747226

CopyrightSaudi Aramco 2009. All rights reserved.

Engineering Procedure SAEP-1150 2 August 2009 Inspection Coverage on Projects

Inspection Engineering Standards Committee Members Kakpovbia, Anthony Eyankwiere, Chairman Rajeh, Saleh Rashid, Vice Chairman Albarillo, Rodolfo Celino Anazy, Khalid Juma Boult, David Carrera, R L Ghamdi, Khalid Salem Ingram, James Young Keen, Peter David Khunaizi, Mohammad Redhi Langla, Edward Charles Mc Ghee, Patrick Timothy Mohsen, Hassan Abdallah Seyed Mohamed, Abdul Cader Shammary, Hamed Abdulwahab Stockenberger, Hans J Suwaidan, Khalid Ali

Saudi Aramco DeskTop Standards Table of Contents 1 Scope............................................................. 2 2 Applicable Documents................................... 2 3 Definitions...................................................... 5 4 Inspection Department (ID) Responsibilities.. 7 5 Inspection Assessment Group (IAG) Responsibilities...................................... 9 6 Vendor Inspection Division (VID) Responsibilities...................................... 9 7 Operations Inspection Division (OID) Responsibilities.................................... 13 8 Projects Inspection Division (PID) Responsibilities.................................... 15

Document Responsibility: Inspection Engineering Standards Committee SAEP-1150

Issue Date: 2 August 2009

Next Planned Update: 1 July 2013 Inspection Coverage on Projects

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Table of Contents (Cont'd) 9 Inspection Department Reporting Responsibilities.................................... 23 10 Deviations to Company Requirements......... 28 Appendix A - Instructions for PID Coverage...... 30 Appendix B - Typical Inspection Points.............. 41 Appendix C - Logbook Format........................... 47 Appendix D - (PQI Format - Procurement Phase)............................ 48 Appendix D - (PQI Format - Construction Phase)............................ 49 Appendix D - (PQI Format - Summary Sheet)... 50

1 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.

2 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 Project Proposal

SAEP-122 Project Records

SAEP-133 Instructions for the Development of Regulated

Vendor Lists

SAEP-302 Instructions for Obtaining a Waiver of a Saudi

Aramco Engineering Requirement

SAEP-303 Engineering Reviews of Project Proposal and

Detail Design Documentation




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SAEP-309 Inspection of Community and Operations Support

Facilities

SAEP-316 Performance Qualification of Coating Personnel

SAEP-318 Pressure Relief Valve Authorization for

Installation, Deletion and Changes

SAEP-319 Pressure Relief Valve Routine Test, Inspection, Quality Assurance and Regulation

SAEP-324 Certification Review and Registration of Project

Welders and Brazers

SAEP-352 Welding Procedures Review and Approval

SAEP-1131 Pressure Relief Valve Program Use of Form

3099-A-ENG, RV Authorization

SAEP-1140 Qualification and Certification of Saudi Aramco

Nondestructive Testing Personnel

SAEP-1141 Industrial Radiation Safety

SAEP-1142 Qualification of Non-Saudi Aramco NDT

Personnel

SAEP-1152 Approval procedure for Ready-Mixed Concrete

Mix Design

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing

SAES-A-005 Safety Instruction Sheet

SAES-A-007 Hydrostatic Testing Fluids and Lay-Up

Procedures

SAES-A-206 Positive Material Identification

SAES-H-101 Approved Protective Coating Systems

SAES-J-600 Pressure Relief Devices

SAES-L-350 Construction of Plant Piping

SAES-P-104 Wiring Methods and Materials

SAES-Q-001 Criteria for Design and Construction of Concrete

Structures

SAES-Q-006 Asphalt Concrete Paving

SAES-T-Series Communications Standards




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SAES-W-Series Welding Standards

SAES-X-Series Cathodic Protection Standards

Saudi Aramco General Instruction

GI-0002.703 Electrical Load Planning and Connection/

Disconnection of Loads to Saudi Aramco's

Distribution System

GI-0002.705 Certification of High Voltage Cable Splicers

GI-0002.710 Mechanical Completion and Performance

Acceptance of Facilities

GI-0150.003 Ionizing Radiation Protection

GI-0400.001 Quality Management Roles and Responsibilities

Saudi Aramco Inspection Requirements

SAER-1972 Saudi Aramco Materials Inspection and Testing

Saudi Aramco Inspection Procedures

00-SAIP-10 Non-Conformance Reports

00-SAIP-12 Equipment Deficiency Report

00-SAIP-13 Projects Assessment Procedure

IAG-01 Internal Assessment

VID-M-016 SAIR Procedures

Saudi Aramco Inspection Forms

VID-3000 Request for Monitoring of Contractor's Source

Inspection

VID-8635 Equipment Deficiency Report

SA-2093 Equipment Inspection Record - General

SA-2642 Pressure Test Report

SA-3099-A-ENG Relief Valve Authorization

SA-4758 Welder Job Clearance Card

SA-6133 Exception Item List

SA-6717-ENG Request for Inspection

SA-8233-2 Splicer Job Clearance Card




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Saudi Aramco Standard Contracts

Schedule A General Terms and Conditions

Schedule B Job Specification

Schedule C Contract Price and Payment Provisions

Schedule E Settlement of Disputes, Arbitration, and Choice of

Law

Schedule F Taxes, Duties, and Related Obligations

Schedule G Materials, Tools and Equipment

Schedule H Special Terms and Conditions

Schedule Q Project Quality Requirements

Drafting Manual

2.2 Industry Standards and Codes

International Standards Organization

ISO 9000 Quality Management System - Fundamentals and

Vocabulary

ISO 9001:2000 Quality Management Systems - Requirements

3 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,




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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.

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.




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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.

4.1.2 Provide QA services in all facets of the Company's Supplier

Qualification and Material and Equipment acquisition.

4.1.3 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.

4.1.4 Provide Quality Assurance services that ensure the safe operation of all

lifting equipment working on Company facilities.

4.2 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.




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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 Develop-

ment

Bid Explanation

Meeting

Technical Bid

Evaluation

Design & Procure-

ment Kick-Off Meeting

Design Phase

Procure- ment

Phase

Cons- truction Kick-off Meeting

Cons- truction Phase

Pre- Commission-

ing Phase

VID X(1)

X(2)

X(5)

X X X

OID X(5)

X(4)

X(4)

PID X(1)

X(2)

X(5)

X(3)

X X X

IAG X(5)

X X X

PQM X X X(5)

X X X X X X

Notes:

1. Attachment VI of Schedule Q, Novaited POs, and Project Quality Plan.

2. Presentation of quality requirements (PID/VID as required).

3. PID reviews design packages.

4. OID reviews NDT procedures and technician certifications.

5. 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




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SAPMT, define project objectives and responsibilities, and outline authorities

and channels of communication.

5 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 Perform quality assessments of contractors' quality programs on LSTK and

LSPB capital projects.

5.2 Perform internal assessments on the activities of Inspection teams and Saudi

Aramco Inspection representatives assigned to LSTK and LSPB capital projects.

5.3 Perform assessments of other internal and external organizations when

requested.

5.4 Compile and report the monthly Project Quality Indices for all applicable

projects (PQI).

5.5 Provide specialized assistance to Projects Inspection and Vendor Inspection

Divisions on project quality requirements.

5.6 Lead Inspection Department's quality enhancement activities.

5.7 Perform quality assurance reviews of comments generated during review of

Contractor quality plans.

6 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.




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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

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




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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.

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




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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 Pre-

inspection 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.

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




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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 sub-

orders 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.

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.

7 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 sub-

contractors. See paragraph 8.12.

7.2 OID NDT Services

7.2.1 Technical Responsibilities

a) Review Contractor NDT procedure for personnel NDT

qualification for compliance with SAEP-1142.




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b) Administer all practical NDT examinations for IK NDT

Contractors.

c) Review and approve all NDT procedures for each project.

d) Conduct Radiographic Film Interpretation assessments.

e) Conduct assessments of Contractor NDT and report performance.

f) Assist PID in resolving disputes on NDT results.

g) Support PID in performing NDT as requested.

h) Provide NDT Level III services to Saudi Aramco organizations as

needed.

7.2.2 Radiation Safety Responsibilities

a) Review and approve the IK NDT Contractor's Radiation Safety

Plan for compliance to SAEP-1141 and GI-0150.003.

b) Interview and approve the IK Contractor's Radiation Safety Officer

(RSO).

c) Issue a "Saudi Aramco Radiographer Permit" for individuals

successfully passing the Loss Prevention Radiation Safety

Examination.

d) Issue radiation safety Advisories and Alerts, as and when required.

e) 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.

f) Inspect and approve IK radiation isotope storage pits located on

Company property.

g) Perform unannounced radiation safety assessments.

h) Investigate Contractor incidents occurring on Company property

and report in accordance with the requirements of SAEP-1141 and

GI-0150.003.

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. Below-

the-hook lifting equipment will be marked with the safe working load and ID




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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.

7.5.2 Civil, Electrical, Mechanical, and Plumbing/HVAC inspection

guidelines for DFIG shall be similar to PID Chapter 8/Appendix A and

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 pre-

commissioning 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.




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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

as, but not limited to, the following:

8.6.1 Introduction of Saudi Aramco Inspection Team Members.

8.6.2 Contractor Quality System requirements.

8.6.3 The use and issuance of RFIs.

8.6.4 The placement and use of Inspection Logbooks.

8.6.5 The submittal of special process procedures (as referenced in Schedule

Q).

8.6.6 The contractor's plan for third party civil testing laboratories, Weld test

Centers, RV Calibrators, NDT testing agencies, and ready mix

concrete/asphalt suppliers.

8.6.7 The submittal of proposed concrete/asphalt mix designs as per

SAEP-1152.

8.6.8 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.

8.7 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




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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

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.




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8.9.2.3 Supply of Blank RFI Forms

SAPMT is responsible to obtain blank RFI forms (SA 6717-

ENG), 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/

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.




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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

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




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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.

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.




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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.

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




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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

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) Preparing the original and revised Project Records in accordance with the

Drafting Manual and SAEP-122.

b) 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.




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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.

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.

9 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.




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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

should precede the logbook entry if practical). The inspection logbook is

utilized to record:

a. Violations observed against the requirements of project documents,

Company standards and procedures, or applicable codes.

b. Inspection observations and comments.

c. Job clarification, recommendations, or any information deemed necessary,

such as the specific location of the violations on the jobsite.

9.3.1 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.

b) 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.




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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.

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) The sequential number of each log book entry.

b) Date and type of inspection (i.e., mechanical, civil, etc.).

c) Inspector's observations, recommendations, and name (printed

clearly).

d) Date of Site Representative's reply. (Normally expected within

3 working days).

e) 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) Date of inspection of corrective action.

h) Inspector's initials of acceptance of corrective action.

RFI and Surveillance Activities Logbook

a) Each page of the logbook shall have a unique sequential number.

b) Date and reference to Inspection discipline.

c) Number of RFI (if applicable).




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d) Indication of whether the work activity was accepted.

e) Any comments or observations by the PID representative.

f) PID representatives name and signature.

9.3.4 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 job-

site 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.

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.




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b) 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.

c) If the Contractor is found in non-compliance with Schedule Q or

to his approved Quality Plan (QP).

d) 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.

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.




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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

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.




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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.

Revision Summary

1 July 2008 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with no other changes.

2 August 2009 Editorial revision to change document responsibility and primary contact.




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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 pile-

diving 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 sub-

grade 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




Page 35 of 50

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) The fit-up, root pass, and hot pass of each weld.

b) Verifying that the Contractor's approved QC Inspector witnesses

and records all observations made during performance of the

entire weld.

c) Ensuring that the Contractor instructs his NDT subcontractor to

use a slow speed film to increase sensitivity of the resultant

radiographic image.

d) Ensuring that once welding starts, it continues without

interruption until completed.

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

SAEP-318, 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-A-ENG) 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-A-ENG) 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 ground-

resistance measurements, cable insulation, and equipment testing. All

installations that are intended to be concealed will be monitored prior to back-

fill 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

SAEP-1150

Documents

Transcript of SAEP-1150