SAEP-35

Engineering Procedure SAEP-35

25 December 2010

Valves Handling, Hauling, Receipt Tests and Storage Document Responsibility: Valves Standards Committee

Saudi Aramco DeskTop Standards Table of Contents 1

Introduction.................................................... 2

2

Conflicts and Deviations................................. 2

3

References..................................................... 2

4

Safety Precaution……......………….……….... 3

5

Handling and Hauling…..................…………. 3

6

Receiving Inspection...…................…………. 4

7

Hydrotest Requirement...................…………. 4

8

Preparation and Test Procedures....……...…. 5

9

Storage Area Requirement…………....……... 6

10

Storage Procedures...…………………..…….. 6

11

Long Term Store Requirement…………...…. 6

Previous Issue: 20 October 2009 Next Planned Update: 20 October 2014 Revised paragraphs are indicated in the right margin Primary contact: Shiha, Saad Mohammed on 966-3-876 0163 Copyright©Saudi Aramco 2010. All rights reserved.

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Document Responsibility: Valves Standards Committee Issue Date: 25 December 2010 Next Planned Update: 20 October 2014

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SAEP-35 Valves Handling, Hauling, Receipt Tests and Storage

Introduction 1.1

Purpose The purpose of this procedure is to establish guidelines for valves supply process to insure their continuous reliability and to preserve their quality throughout the whole process of transportation, receipt, testing and storage.

1.2

Scope This procedure is intended only to provide general guidelines for valve handling, hauling, receipt, testing and storage. It shall be noted that this document is intended as a guideline and minimum requirements only, as it may not cover all possible variations and combinations of specific valve type. Manufacturer's instructions take precedence in the event that they conflict with these guidelines.

2

Conflicts and Deviations Any conflicts between this procedure and other applicable Saudi Aramco Engineering Standards (SAESs), Materials System Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing to the Valves Standards Committee Chairman (VSCC).

3

References The requirements contained in the following documents apply to the extent specified in this procedure. 3.1

Saudi Aramco References Saudi Aramco Engineering Standard SAES-A-004

General Requirements for Pressure Testing

Saudi Aramco Materials System Specifications 04-SAMSS-035

General Requirements for Valves

04-SAMSS-048

Valve Inspection and Testing Requirements

Saudi Aramco Inspection Checklists SAIC-A-2009

Verification of Test Preparation and test Equipment for Pressure Testing

SAIC-A-2015

Visual Inspection of Pressure Test

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Document Responsibility: Valves Standards Committee Issue Date: 25 December 2010 Next Planned Update: 20 October 2014

SAEP-35 Valves Handling, Hauling, Receipt Tests and Storage

SAIC-A-2017

Depressurization & Disposal of Hydrotest Water

SAIC-L-2040

Receiving Inspection of Manual Valves

SAIC-L-2041

Storage and Preservation of Valves

SAIC-L-2042

Field Hydrostatic Testing of Isolation Valves

Saudi Aramco General Instruction GI-0002.102 3.2

Pressure Testing Safely

Industry Codes and Standards American Petroleum Institute API STD 598

Valve Inspection and Testing

API STD 6D

Pipeline Valves

British Standards BS 6755 Part 2 4

Testing of Valves

Safety Precautions Certain precautionary steps must be addressed clearly and adhered to prior to and during the performance of Hydrostatic Testing of valves and transportation such as, but not limited to the following:

5

i)

Prior to starting any work, all requirement of GI-0002.102 is fulfilled.

ii)

Personnel involved with the testing and inspection shall be adequately trained.

iii)

Use only designated lift lugs for lifting.

iv)

Tools must be inspected to be fit for service, including sling wires and tie connection.

v)

Never try to open or make repairs to any pressurized part of the valve before depressurizing and verifying no trapped pressure exists.

vi)

Work area must be prepared; accessibility must be fully provided and inspected.

Handling and Hauling 5.1

Special cares and consideration shall be taken during handling and transporting of valves against mechanical.

5.2

Critical points of the valves such as the valve end ports and stem shall be protected.

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Document Responsibility: Valves Standards Committee Issue Date: 25 December 2010 Next Planned Update: 20 October 2014

Valves Handling, Hauling, Receipt Tests and Storage

5.3

All valves shall comply with 04-SAMSS-035 shipment preparation requirement during transportation, handling and field storing at all times.

5.4

Valves shall be restrained from movements during transportation to avoid any damages to the main valve and its accessories.

5.5

Small size valves shall be positioned carefully to prevent any damage.

5.6

Transportation, lifting and handling of valves shall be carried out safely by appropriate equipment and trained personnel. Note:

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SAEP-35

Handwheels, stems, gears, actuators or any other accessories shall never be used as lifting points.

Receiving Inspection Receiving inspection shall be performed prior to transfer of custody to insure no damage has occurred during transportation and handling. A standard inspection checklist SAIC-L-2040 can be used for full check of valves integrity.

7

Hydrostatic Requirement Hydrostatic tests shall be carried as per below requirements and against the standard inspection checklist SAIC-L-2042 Field Hydrostatic Testing of Isolation Valves. 7.1

Test Location The following requirements shall be available in the test locations: a)

The location/shop: It shall not introduce any foreign materials that could intervene with the valve functions such as dirt/sand or other hard particles. The location should have means of protections. Commentary Note: During site testing, the weather conditions must be suitable for performing the test.

7.2

b)

Valves fixtures: Valves should be supported off the ground and restrained from any free movement.

c)

Floor profile: Flooring shall be hard such as concrete floor, paving or any sort tiling.

Testing Equipment Capability a)

Blinds: they shall be matching with the same rating and type of the valve ends. Both blinds shall be provided with pressure/vent connections.

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Document Responsibility: Valves Standards Committee Issue Date: 25 December 2010 Next Planned Update: 20 October 2014

7.3

SAEP-35 Valves Handling, Hauling, Receipt Tests and Storage

b)

Blind/bolts conditions. They must be clean and shall not have signs of corrosion.

c)

Pressure gauges: the test pressure shall not be less than 30% no greater than 80% of the full scale range of the pressure gauge. All instruments shall have the calibration certificates.

d)

All connections must have the proper pressure ratings.

e)

The pressure reliefs and their setting must comply with SAES-A-004.

Test Fluid The fluid quality shall be within the acceptable criteria of API STD 6D, API STD 598 or BS 6755 Part 2.

8

Test Procedure The following requirements need to be available in order to perform the hydrostatic testing: 8.1

Prior to commencing the testing, a test procedure shall be developed in accordance with 04-SAMSS-048, SAIC-A-2009, SAIC-A-2015 and SAIC-L-2042.

8.2

Manufacturer instructions and guidelines shall be taken into consideration.

8.3

The procedures shall address the following as minimum requirement: i)

The set pressures for hydrostatic shell test and/or seat test.

ii)

Test durations.

iii)

Acceptable leakage rates.

iv)

Sequence of testing

v)

Stabilization periods.

vi)

Monitoring procedures.

vii)

If the valve is equipped with Double-Piston Effect (DPE) feature, the procedure shall include steps to test this seat configuration.

viii)

Draining, drying procedures: The procedure shall specify the draining, dewatering procedure. Assurances of completely dried valve shall be clearly mentioned such as blowing of hot or dried compressed air, controlled dew point, inert gas or other methods to remove all test medium residuals.

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Document Responsibility: Valves Standards Committee Issue Date: 25 December 2010 Next Planned Update: 20 October 2014

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SAEP-35 Valves Handling, Hauling, Receipt Tests and Storage

ix)

Corrosion prevention, upon completion of drying process, means of corrosion inhibition and lubrication shall be applied as applicable.

x)

Upon completion of the testing, valves shall be restored to the original packing condition if installation time is not immediately after the testing as per 04-SAMSS-035 and/or SAIC-L-2041.

Storage Area Requirements 9.1

The store area should provide means of protections against severe weather conditions such as sand encroachment, rains, and other conditions that can affect valves integrity.

9.2

Valves should be supported off the ground.

Valves Storing Procedures 10.1

New valves shall be stored with their packaging unopened, or if inspected shall be restored accordingly.

10.2

For packaging of unpacked valves please refer to 04-SAMSS-035 or SAIC-L-2041.

Long Term Store Inspections (Any storage for a period of three months and longer shall be considered as long term store) 11.1

At least once every 3 months, the valves shall be visually inspected to check the integrity of the covers, caps, grease and other visible conditions.

11.2

Prior to installation, long term stored valves shall be re-tested.

20 October 2009 25 December 2010

Revision Summary New Saudi Aramco Engineering Procedure. Editorial revision to reflect the changes in committee members list.

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