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Engineering Procedure

SAEP-1150 31 May, 2004


Inspection Coverage on Projects
Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards


Table of Contents

1 Scope............................................................. 2
2 Applicable Documents................................... 2
3 Definitions...................................................... 5
4 Inspection Department (ID) Responsibilities.. 6
5 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...... 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

Previous Issue: 31 March, 2002 Next Planned Update: 1 June, 2007


Revised paragraphs are indicated in the right margin Page 1 of 49
Primary contact: Abdulbaqi M. Al-Nasser on 862-6120
Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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
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
3099A, RV Authorization
SAEP-1140 Qualification and Certification of Saudi Aramco
Nondestructive Testing Personnel
SAEP-1141 Industrial Radiation Safety

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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
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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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
2093 Equipment Inspection Record - General
2642 Pressure Test Report
3099-A-ENG Relief Valve Authorization
4758 Welder Job Clearance Card
6133 Exception Item List
6717-ENG Request for Inspection
8233-2 Splicer Job Clearance Card

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

Page 4 of 49
Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

ISO 9000 Quality Management System - Fundamentals and


Vocabulary

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, 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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 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.

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.

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.

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
Cons-
Design
Project tructio
Technical & Procur Cons-
Proposa Bid Desig n Pre-
Bid Procure- e- tructio
l Explanation n Kick- Commission-
Evaluatio ment ment n
Develop- Meeting Phase off ing Phase
n Kick-Off Phase Phase
ment Meetin
Meeting
g
VID X(1) X(2) X(5) X X X
(5)
OID X X(4) X(4)
PID X(1) X(2) X(5) X(3) X X X
(5)
IAG X X X X
PQM X X X(5) X X X X X X

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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
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.

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.

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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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 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.

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 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.

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.
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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

(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
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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.

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:

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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
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.

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 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.

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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


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.

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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.

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

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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 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

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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
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.

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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.

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

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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.

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

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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.

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

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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).
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

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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.

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

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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
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

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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.

Revision Summary
31 May 2004 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with minor 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 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.

A.7.1.3 Pouring & Post-Pouring Inspections

PID will witness most concrete pours and monitor concrete

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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.

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

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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.

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

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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
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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.

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,

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.
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

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 (A-3099A)
against the P&ID and calculation sheets. PID will inspect the installation of the
relief valve, and sign the verification portion of Form (A-3099A). Assignment
of identifying numbers and entry of the approved Form (A-3099A) will be
arranged through the Relief Valve Administrator of OID.

Page 37 of 49
Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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 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
MCCs, will be carried out as per the responsibilities designated by the

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

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.

Page 39 of 49
Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

Appendix B – Typical Inspection Points

B.1 Protective Coatings (External and Internal)


B.1.1 Personnel qualification
B.1.2 Surface preparation prior to coating
B.1.3 Paint Mixing
B.1.4 DFT Readings
B.1.5 Tests (Adhesion, Holiday, etc.)
B.1.6 Prior to top coat for APCS-4 or 6
B.1.7 Application of heat shrink sleeves
B.1.8 Coating repair

B.2 Welding
B.2.1 Welding procedure and Welder qualifications
B.2.2 Non-destructive testing Procedures, Personnel, and activity start-up
B.2.3 Start of fabrication and welding activities
B.2.4 Selection of points for NDT
B.2.5 Radiographic film interpretation by Company certified Interpreters
B.2.6 Repair of cracked welds
B.2.7 Stress relieving
B.2.8 Tie-in welds
B.2.9 Socket weld gap and thread engagement

B.3 Brazing
B.3.1 Brazing procedure
B.3.2 Brazer qualifications
B.3.3 Certification of brazed joint at job site

B.4 Post-weld Heat Treatment


B.4.1 Approved procedure
B.4.2 Calibration of measuring devices
B.4.3 Documentation
B.4.4 Hardness testing

B.5 Piping/Pipelines
B.5.1 Pipe bending
B.5.2 Lowering-in of pipeline sections

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

B.5.3 Lay-up of piping/pipelines


B.5.4 Road crossings
B.5.5 Thrust boring

B.6 Plant Piping


B.6.1 Flange and fitting type and rating
B.6.2 Gasket type and installation
B.6.3 Bolt Torquing
B.6.4 Piping re-instatement after hydrostatic test
B.6.5 Hot taps and stopple installation

B.7 Vessels
B.7.1 Lay-up of vessels
B.7.2 Vessels closure

B.8 Pressure testing


B.8.1 Calibration of pressure gauges and relief valves for use in pressure
testing when performed by other than approved testing agency
B.8.2 Punchlisting prior to pressure test/review of test package
B.8.3 Filling and venting
B.8.4 Stabilization
B.8.5 Pressurization

B.9 Pressure Relieving Devices


B.9.1 Documentation verification
B.9.2 Installation verification

B.10 Plumbing
B.10.1 Sand bedding and cover
B.10.2 Head test, sanitary lines
B.10.3 Pressure test, water lines
B.10.4 Test sanitary manholes
B.10.5 Closing of walls and ceilings

B.11 HVAC
B.11.1 Prior to installation of duct insulation
B.11.2 Installation of HVAC units
B.11.3 Fire dampers & sleeves in fire rated walls

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

B.11.4 Brazing and soldering of refrigeration lines


B.11.5 Pressure test, refrigeration lines
B.11.6 Vacuum testing of refrigeration lines
B.11.7 Testing and balancing of HVAC system
B.11.8 Closing of walls and ceilings

B.12 Civil
B.12.1 Prior to closure of formwork
B.12.2 Prior to concrete placement, grouting, and asphalting
B.12.3 Prior to bituminous coating of buried concrete structures
B.12.4 Prior to asphalt roofing placement
B.12.5 Prior to commencement of the initial bending of epoxy coated
reinforcing bar
B.12.6 Verify that a geo-technical survey has been carried out
B.12.7 Prior to closure of walls and ceilings
B.12.8 Bottom of excavations
B.12.9 After preparation of the bottom of foundations
B.12.10 Before backfilling around structures
B.12.11 After preparing the existing sub-grade, and after each layer for road
construction
B.12.12 Sand cover of piping
B.12.13 Concrete prior to any repair

B.13 Electrical

B.13.1 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 Prior to backfilling of direct buried cable or conduit
B.13.1.2 Prior to covering cable conduit within a permanent wall,
ceiling, floor, or tank bottom
B.13.1.3 Prior to burying a grounding connection, i.e.: thermite
welding (cadweld), brazing, or approved compression
connectors
B.13.1.4 Prior to burying a splice on a cable rated above 1000 volts
B.13.1.5 Prior to burying cathodic protection anodes and
connections
B.13.1.6 Thermite welding (cadweld) of cathodic protection cables

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

to buried pipelines
B.13.1.7 Witness of instrument calibrations
B.13.1.8 Witness leak testing of process tubing
B.13.2 Cable splicer certification for cable rated above 1000 volts.
(GI-0002.705 & SAES-P-104)
B.13.3 Prior to wires/cables pulled into conduits or cable trays
B.13.4 Prior to energizing a cable or piece of equipment. (GI-0002.703)
B.13.5 Grounding and electrode earth resistance tests
B.13.6 Installation, cable pulling, damming, and compound pouring of all
conduit sealing fittings
B.13.7 Cathodic Protection
B.13.7.1 Completion of bonding station installations.
B.13.7.2 Testing of impressed current anode cables (dielectric
testing).
B.13.7.3 Completion of station installations for pipelines.
B.13.7.4 Resistance measurements for deep anode bed test anodes.
B.13.8 Testing of illumination levels
B.13.9 Instrumentation loop checks
B.13.10 Instrumentation calibration

B.14 Communications

B.14.1 Buried Cable


B.14.1.1 Trench before installation of the sand pad
B.14.1.2 Cable during placing operation
B.14.1.3 Marker tape installation

B.14.2 Underground conduit


B.14.2.1 Trench before installation of the conduit
B.14.2.2 Conduit before concrete encasement including mandrel
testing
B.14.2.3 Marker tape/orange dye installation

B.14.3 Manholes
B.14.3.1 Excavation for bracing/shoring when depth reaches 5' and

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

until completion
B.14.3.2 Internal form work before pouring concrete for duct
terminators, inserts, etc.
B.14.3.3 Grounding connections when rods are outside of manhole
B.14.3.4 Ring and cover frame installation

B.14.4 Underground cable placement


B.14.4.1 Reel set-up and choice of duct
B.14.4.2 Tensiometer
B.14.4.3 Mandrel test ducts
B.14.4.4 Cable and cable pulling

B.14.5 Cable splicing


B.14.5.1 Underground – check cable racking in manhole
B.14.5.2 Splice connectors, after 50 pairs or less, after 600 pairs or
less, and after every 600 pairs on larger cables
B.14.5.3 Completed splice before closing case

B.14.6 Communications work in Buildings


B.14.6.1 Underground entrance conduit before concrete
encasement, including mandrel testing
B.14.6.2 Closet/equipment room requirements prior to and during
construction
B.14.6.3 Distribution system design before start of installation
B.14.6.4 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
B.15.1.1 Factory operational and any required proof load tests
conducted and witnessed by V.I.D
B.15.1.2 Test certificates showing conformance of all material and
assemblies to the specified codes and standards, including

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Document Responsibility: Inspection Department SAEP-1150
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Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

pre-delivery inspection and test results


B.15.1.3 Clearly marked capacity in Arabic and English in metric
units of measurement
B.15.1.4 Valid Saudi Aramco Crane Safety Inspection Sticker
B.15.1.5 All initial inspection and load tests following installation
of the equipment
B.15.1.6 All reinstalled, altered, modified, or extensively repaired
cranes and lifting equipment
B.15.1.7 Inspection and load tests, and periodic load tests as
required by the relevant standard, shall be witnessed by
Saudi Aramco Crane Inspection Group

B.15.2 Mobile cranes, and Side-boom Tractors


B.15.2.1 Valid Saudi Aramco Crane Safety Inspection Sticker
B.15.2.2 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
B.15.2.3 Any crane which has undergone a boom modification or
re-configuration shall require re-inspection by Saudi
Aramco Crane Inspection Group

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.

Page 45 of 49
Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

Appendix C – Logbook Format

INSPECTION
INSPECTION DEPARTMENT SAPMT
DEPT.

Entry SIGN OFF


Date DATE REPLY
No. & DATE

1 MM/DD/YY Civil MM/DD/YY The contactor was

Steel plates and the bars instructed to comply

used in the pipe support with the Standard

foundations were neither requirement, and the

galvanized nor coated with required coating with

zinc rich epoxy primer zinc rich epoxy is in

(APCS-1C of SAES-H-101). progress Completed

This violates SAES-Q-001, MM/DD/YY

Section 6.4. (Full name) D.D. Barry B. Al-Basher

(Full name) B. Al-Basher

Page 46 of 49
Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

Appendix D – (PQI Format - Procurement Phase)

INSPECTION DEPARTMENT
DESIGN & PROCUREMENT QUALITY INDEX

Item INDICES Comments


Submittal
Quality of
1 Document Submittal per Schedule Q MAX On Time Comments
Submittal
or Late
Quality Plan, Procedures and Audit Schedule 2
1.1
Quality Manager within 7 days of Notice to Proceed 2
1.2
Quality Personnel resumes 2
1.3
2
1.4 Purchase Requisitions
2
1.5 Supplier selection/evaluation
2
1.6 Special Process Procedures
2
1.7 Inspection Assignment Packages with IT&P
2
1.8 Two-week Look-Ahead Schedules
2
1.9 Weekly Insp. Status/ Fabrication Report for Inspection
2
1.10 Inspection Reports (Pre-inspection, in-process, final)
2
1.11 Audit Reports
2
1.12 Non-conformance Reports
2
1.13 Weekly NCR Sumamry
2
1.14 Monthly Quality Management Reports
Management Review Results 2
1.15
Final Disposition Reports 2
1.16
Quality of
2 Quality System Implementation
Implementation
Equipment/Material inspection levels agree with Schedule 'Q' 4
2.1
Vendors and contractor Inspectors work to latest approved technical 4
2.2
2.3 documents
Design reviews are scheduled and completed on time 4

Review of suborders 4
2.4
Pre-inspection Meetings coordinated and covered all requirements 4
2.5
Reliablity of 2-week Look-ahead Schedule 4
2.6
Inspection carried out by approved inspectors 4
2.7
Contractor review of sub-orders 4
2.8
Approved ITP's have been fully implemented 4
2.9
All vendor documentation reviewed and verified 4
2.10
Internal audits performed as scheduled 4
2.11
Preventive actions are identified and implemented 4
2.12
Non-conformities identified and documented and reported to Saudi 4
2.13

2.14 Aramco
Root-Cause is identified and corrective action is implemented and 4

2.15 accepted of NCR issued by contractor


Percentage 4
Procurement
3 Quality of Procured Material
Quality
Exception Items have been identified and documented 5
3.1
Quality of Material delivered to site 5
3.2
Vessels, Tanks and Exchangers 5
3.3
Boilers and Furnaces 5
3.4
Mechanical Equipment 5
3.5
Positive Material Identification for Alloy material 5
3.6
Pipes, fittings, flanges - Process/Pipelines 5
3.7
Valves 5
3.8
Packaged Equipment 5
3.9
Rotating Equipment (pumps, turbines, compressors, etc.) 5
3.10
Electrical Equipment (motors, generators, MCC, Switchgear, cables, etc.) 5
3.11
Structural Steel and Pre-Fabricated Buildings 5
3.12
Process Control Systems (Panels, controllers, instrumentation) 5
3.13
Mfg. Data Books reviewed and approved prior to IRC 5
3.14

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

Appendix D – (PQI Format - Construction Phase)

hansito INSPECTION DEPARTMENT hansito


CONSTRUCTION QUALITY INDEX

Item INDICES Comments


Submittal
Quality of
1 Document Submittal per Schedule Q MAX On Time
Submittal
or Late
1.1 Quality Plan & Systems Procedures and Audit Schedule 2
1.2 Inspection and Test (ITP) Plan & Procedures 2
1.3 Quality Manager submitted within 7 days of Notice to Proceed 2

1.4 Quality Personnel resumes 2

1.5 Current Monthly list of Quality personnel 2


1.6 Special Process Procedures 2
1.7 Two-week Look-Ahead Schedules 2
1.8 Inspection and Test Reports 2
1.9 Audit Reports 2
1.10 Non-conformance Reports 2
1.11 Weekly NCR Summary 2

1.12 Quality Management Reports 2


1.13 Management Review Results 2

Quality of
2 Quality System Implementation
Implementation

2.1 Quality manpower level on site per Schedule Q, Attachment VI 4


2.2 Drawings and Technical documents controlled 4
2.3 Field changes documented, approved and distributed 4

2.4 Welding complies with applicable standards and procedures 4

2.5 Inspections performed per I&TP and documented per procedures 4


2.6 Inspection waivers requested 4
2.7 Inspection Status maintained for all work 4
2.8 Material Receiving per procedures 4
2.9 Traceability maintained as required 4
2.10 Material Handling, Storage & Preservation per procedures 4
2.11 Measuring and Test equipment calibrated per prescribed period 4
2.12 Internal Audits are performed, documented and followed up 4

2.13 Sub-contractor audits performed, documented and followed up 4


2.14 Quality Records maintained and retrievable 4
2.15 Preventive actions are identified and implemented 4
2.16 Non-conformaties identified and documented 4
2.17 Root-Cause is identified and corrective action is implemented 4
2.18 Percentage of NCR issued by contractor 4
Construction
3 Quality of Construction work
Quality
3.1 Percentage of RFI accepted 5
3.2 HVAC and Building Finshing 5

3.3 Testing and mixing and placement of concrete & asphalt 5

3.4 Manual Weld Reject Defect rate below 5% 5


3.5 Positive Material Identification (PMI) implemented 5
3.6 Piping, Fittings, Flanges & pressure testing - Utilities 5
3.7 Piping, Fittings, Flanges & pressure testing - Process and/or Pipelines 5
3.8 Valve pressure tests 5
3.9 Gasket Installation & Bolt Torquing (Piping) 5
3.10 Paint & Coating (Total DFT, Holiday, Cure, Adhesion) 5

3.11 Cable splicing and termination 5

3.12 Conduit sealing 5

3.13 Bolt Torquing of critical structural joints 5


3.14 Relief valves calibrated, installed and carsealed. 5
3.15 Percentage of Contractor generated Puch List items 5
3.16 Percentage of 'NO' items closed at MCC 5

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Document Responsibility: Inspection Department SAEP-1150
Issue Date: 31 May, 2004
Next Planned Update: 1 June, 2007 Inspection Coverage on Projects

Appendix D – (PQI Format - Summary Sheet)

INSPECTION DEPARTMENT

PROJECT QUALITY INDEX

BI/JO: Title:

MONTH: Contractor:

VALUE $: % Complete:

PROCUREMENT PHASE EVALUATOR:

# INDICES PQI COMMENTS


Document Submittal
1 #DIV/0!
Quality System Implementation
2 #DIV/0!
Quality of Procured Material
3 #DIV/0!
PROJECT PROCUREMENT QUALITY INDEX #DIV/0!
WEIGHT : 40% of PQI

CONSTRUCTION PHASE EVALUATOR:

# INDICES PQI COMMENTS


Document Submittal
1 #DIV/0!
Quality System Implementation
2 #DIV/0!
Quality of Procured Material
3 #DIV/0!
PROJECT CONSTRUCTION QUALITY INDEX #DIV/0!
WEIGHT : 60% of PQI

PROJECT QUALITY INDEX: #DIV/0!

Signed by:
Inspection Representative

Signed by:
SAPMT Representative

Signed by:

Contractor Representative

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