Safety Instruction Sheets For Plant Piping and Cross-Country Pipelines

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
SAFETY INSTRUCTION SHEETS FOR PLANT PIPING AND CROSS-COUNTRY PIPELINES
Note: The source of the technical material in this volume is the Professional Engineering Development Program (PEDP) of Engineering Services. Warning: The material contained in this document was developed for Saudi Aramco and is intended for the exclusive use of Saudi Aramcos employees. Any material contained in this document which is not already in the public domain may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used in whole, or in part, without the written permission of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Mechanical File Reference: MEX-101.10
For additional information on this subject, contact PEDD Coordinator on 874-6556
Piping, Pipelines & Valves Safety Instruction Sheets for Plant Piping and Cross-Country Pipelines
MODULE COMPONENT
PAGE
INTRODUCTION .................................................................................................2 DETERMINING THE INFORMATION REQUIRED FOR PLANT PIPING............4 Critical Plant Piping Systems ....................................................................4 Information Contained in Saudi Aramco Form 2821 .................................5 DETERMINING THE INFORMATION REQUIRED FOR CROSS-COUNTRY PIPELINES ..........................................................................................................7 Information Contained in Saudi Aramco Form 5645-1 ..............................7 Information Contained in Form 5645-1, Cont'd .........................................8 Information Contained in Saudi Aramco Form 5645-2 ..............................9 SUMMARY ........................................................................................................10 Line Identification (Entries 1-6)................................................................11 Equipment Data (Entries 7-16)................................................................11 Operating Limits (Entries 17-28) .............................................................13 Miscellaneous Information (Entries 29-35) ..............................................16 Work Aid 2A: Saudi Aramco Form 5645-1............................................18 Pipeline Identification (Entries 1-12)........................................................18 Equipment Data (Entries 13-24)..............................................................20 Operating Limits (Entries 25-40) .............................................................22 Miscellaneous Information (Entries 41-48) ..............................................25 Work Aid 2B - Saudi Aramco Form 5645-2 .............................................27 Pipeline Identification (Entries 1-9)..........................................................27 Equipment Data (Entries 10-20)..............................................................28 Operating Limits (Entries 21-37) .............................................................29 Operating Limits (Entries 21-37), Cont'd .................................................29 Operating Limits (Entries 21-37), Cont'd .................................................31 Miscellaneous Information (Entries 38-45) ..............................................31 GLOSSARY .......................................................................................................34
INTRODUCTION Safety Instruction Sheets are used to ensure that operations, maintenance, and inspection personnel will have adequate information that concerns safe operating limits, protective devices, any special safety precautions for specified piping system or pipelines, and other equipment items in a consistent format. The Saudi Aramco engineer must know how to complete all the items on the applicable Safety Instruction Sheet, including Maximum Allowable Operating Pressure (MAOP), pipewall thickness, pressure test requirements, and numerous other items that were previously discussed in this course. The Saudi Aramco engineer is responsible for the completion of the form, the audit of the contents of the form, and ensuring that it is included in the design package. The Safety Instruction Sheets applicable to piping systems are as follows: Saudi Aramco Form 2821. Saudi Aramco Forms 5645-1 and 5645-2.
Saudi Aramco Form 2821 is used for plant piping systems, and Forms 5645-1 and 5645-2 are used for cross-country pipelines. The extent of their use for these systems will be discussed in later sections. These forms provide a permanent record of critical data with regard to the piping system. In particular, pipe material, design conditions, thicknesses, MAOP, and safety-valve set pressures are specified on these sheets. By the time these forms are completed, the piping system design has been done, and all the information that is necessary to complete these forms is readily available. Thus, no additional engineering is required to complete these forms. An engineer can obtain a fairly complete picture of the design of the piping system from the Safety Instruction Sheets. The Safety Instruction Sheets are part of the permanent records for the system and are a critical
resource when changes or maintenance are required on the piping system. These forms must be completed before the system is put into operation. They are completed throughout the design of the piping system, and they are referred to during inspection and testing. Saudi Aramco Engineering Standard SAES-A-005, Safety Instruction Sheet, provides requirements and instructions for the completion of the appropriate form for a particular situation. SAES-A-005 should be referred to when a Safety Instruction Sheet is being completed.
DETERMINING THE INFORMATION REQUIRED FOR PLANT PIPING Critical Plant Piping Systems SAES-A-005 requires that Safety Instruction Sheet, Saudi Aramco Form 2821, be completed for critical plant piping. A piping system is determined to be critical based on operational considerations, design conditions that make it more difficult to design and/or prone to failure, or safety considerations. A plant piping system is critical if it meets at least one of the following criteria: The failure of the system would lead to a major shutdown of the plant, or shutdown of a major unit of the plant. The design temperature is 340C (650F) or higher. The design pressure is 3,450 kPa (500 psig) or higher. The fluid that is contained in the pipe is toxic or very corrosive. There is some other specific operating hazard associated with the system that is not normally experienced with the usual plant or process lines.
Saudi Aramco Form 2821 is normally not completed for piping systems that are covered by Piping Material Specification Classes D, E, F, G, or H of SAES-L-005. These Specification Classes are relatively mild in nature, as follows: Class D Low-Pressure Utilities, Noncorrosive Class E Low-Pressure Utilities, Corrosive Class F Nonpressure Sewers Class G Small Diameter Piping Around Pumps and Compressors Class H Low-Pressure Hydrocarbon Service
Refer to SAES-L-005 for the specific service limitations of these Classes.
Information Contained in Saudi Aramco Form 2821 Saudi Aramco Form 2821 identifies system design information for plant piping systems. The design information that is identified on Saudi Aramco Form 2821 must be determined in order to complete the form. Work Aid 1 contains a copy of Form 2821 (Figure 1) with each entry area numbered. Work Aid 1 also contains a procedure that may be used to complete the form and is keyed to the numbered areas. Form 2821 identifies four primary categories of information as follows: Line Identification Information. These items identify the line with respect to line number, end points, fluid service, other reference drawings, and the industry code that was used for its design. Equipment Data. These items define the primary physical design information for the system, such as diameter, nominal wall thickness, material, and flange rating. This information helps personnel define many of the physical characteristics of the system without the need to locate the detailed engineering drawings. Additional needed information can be found as required because the design drawings are also referenced. All of this information was determined during the system design and most was discussed in earlier modules of MEX 101.
Operating Limits. These items define the primary operating limits for the system, such as design pressure and temperature, MAOP, test pressure, and the component(s) that limit the system operation. This information permits personnel to perform an initial evaluation of the system to determine its limitations. This may be required if a rerate is being considered, or if corrosion has occurred. All of this information was determined during the system design and most was discussed in earlier modules of MEX 101. Miscellaneous Information. This section contains additional information regarding location, identification, and locations for the necessary approvals.
Refer to Work Aid 1 and Figure 1 for the specific information that is contained in each of these categories and for a procedure for completing this form.
DETERMINING THE INFORMATION REQUIRED FOR CROSS-COUNTRY PIPELINES In general, Safety Instruction Sheets are prepared for all flowlines, trunklines, and cross- country pipelines that carry any fluid. Saudi Aramco Form 5645-1 shall be completed for all major pipelines. In addition, Saudi Aramco Form 5645-2 shall be filled out for the same pipelines to cover tie-in piping, scraper traps and their appurtenances, jumpovers, flanges, fittings, any special components, road crossings, and sun pressure relief valves. Form 5645-2 shall also be prepared for flowlines, trunklines, testlines, and submarine pipelines. Both Forms 5645-1 and 5645-2 are to retain the same Saudi Aramco drawing number when they are used for different portions of the same general pipeline, but with different sheet numbers. When calculations are required to complete the form, the issuer of the forms must attach a calculation sheet with each form to help with any later review that might be required. The calculation sheet shall show the method that was used to achieve calculated values, such as formulas, individual variables that are in the formulas with their units, specific requirements from the relevant standards, etc. Information Contained in Saudi Aramco Form 5645-1 Saudi Aramco Form 5645-1 identifies system design information for cross-country pipelines. The design information that is identified on Saudi Aramco Form 5645-1 must be determined in order to complete the form. Work Aid 2A contains a copy of Form 5645-1 (Figure 2) with each entry area numbered. Work Aid 2A also contains a procedure that may be used to complete the form and is keyed to the numbered areas. Form 5645-1 identifies four primary categories of information as follows: Pipeline Identification Information. This includes items such as the pipeline's official designation, end points, fluid service, the year it was built, valve
operating diagram reference, the number of sheets that describe the entire pipeline, reference to the Forms 5645-2 that are also used for the pipeline, and the pipeline segment numbers that are covered by the sheet. Equipment Data. These items define the primary physical design information for the pipeline segments that are covered by a particular sheet. This includes items such as diameter, nominal wall thickness, material, flange rating, and whether the pipeline is buried or aboveground. This information helps personnel define many of the physical characteristics of pipelines without the need to locate the detailed engineering drawings or go into the field. All of this information was determined during the pipeline design, and most was discussed in earlier modules of MEX 101.
Information Contained in Form 5645-1, Cont'd Operating Limits. These items define the primary operating limits for the pipeline. This includes items such as the MAOP of each segment and the overall system (and the component[s] that limit them), the Design Factor of each segment, maximum design temperature, minimum tie-in temperature, minimum required thickness, and test pressure. This information permits personnel to perform an initial evaluation of the pipeline to determine its limitations. This evaluation may be required if an alternate operation is being considered, or if corrosion has occurred. All of this information was determined during the system design, and most was discussed in earlier modules of MEX 101.
Miscellaneous Information. This area contains additional information regarding location, identification, and locations for the necessary approvals.
Refer to Work Aid 2A and Figure 2 for the specific information that is contained in each of these categories, and for a procedure for completing this form. Information Contained in Saudi Aramco Form 5645-2 Saudi Aramco Form 5645-2 identifies system design information for flowlines, trunklines, testlines, submarine pipelines, tie-in piping, scraper traps and their appurtenances, special components, and the other items that were noted previously. Work Aid 2B contains a copy of Form 5645-2 (Figure 3) with each entry area numbered. The design information that is identified on Saudi Aramco Form 5645-2 must be determined in order to complete the form. Work Aid 2B also contains a procedure that may be used to complete the form and is keyed to the numbered areas. Saudi Aramco Form 5645-2 identifies the same four primary categories of information that were discussed for Saudi Aramco Form 5645-1. However, the specific data items that are included in the "Equipment Data" and "Operating Limits" categories are more similar to the items that are in Form 2821 for plant piping rather than in Saudi Aramco Form 5645-1; the similarity exists because the particular pipeline system items for which Saudi Aramco Form 5645-2 is used are more similar to plant piping than to cross-country pipelines. Refer to Work Aid 2B and Figure 3 for the specific information that is contained in each of these categories and a procedure for completing this form.
SUMMARY Safety Instruction Sheets must be completed before a piping system can go into operation. For critical plant piping systems, Form 2821 must be completed. For cross-country pipelines, Saudi Aramco Forms 5645-1 and 5645-2 must be completed. The completion of these forms requires the engineer to collect information regarding system design and operating limits that has already been determined during detailed engineering. The collection of data in this manner ensures that operations, maintenance and inspection personnel have adequate information in a consistent format. The next module discusses how to maintain piping and repair defects after the piping system has been placed in operation.
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WORK AID 1:
PROCEDURES FOR DETERMINING THE INFORMATION TO COMPLETE A SAFETY INSTRUCTION SHEET FOR PLANT PIPING Use the following procedure, in conjunction with Figure 1, to determine the information that is necessary to complete Safety Instruction Sheet, Form 2821, for critical plant piping. The identification numbers that are shown in the following procedure correspond to those shown in Figure 1. Reference SAES-A-005, Safety Instruction Sheet, for additional information. Note that by the time it is necessary to complete Form 2821, engineering has been completed, all the required information is readily available, and no new calculations or selections are needed.
Line Identification (Entries 1-6) 1. 2. & 3. Show the line identification number, such as P28-3A1. Indicate where the line starts and ends, such as Furnace F-201 to Column C-221, Acid Pumps G-21A/B to Reactor D-21. Give specific data on the fluid service, such as reduced crude with acid, vapor, etc. Indicate the pertinent pipe isometrics, P & ID's, or other reference drawings that apply to the particular line. Show the applicable industry code and year that was used in the pipe design, such as ANSI B31.3, 1990.
4. 5.
6.
Equipment Data (Entries 7-16) Note that there are three columns within the Equipment Data area. This permits providing information about three separate pipe sizes or materials that may be within
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the same piping system. 7. 8. Nominal pipe size (NPS). Pipewall thickness in inches or millimeters. Note that this is the nominal pipe thickness, which was discussed in MEX 101.03. Pipe material specification and grade, such as A-106, Gr. B, API 5L, Gr. X-42. Material selection was discussed in MEX 101.02 and MEX 101.08.
9.
Equipment Data (Entries 7-16), Cont'd 10. Indicate whether the pipe has a welded longitudinal seam (such as SAW, ERW), or is seamless (SMLS). Flange rating according to ASME/ANSI B16.5. Selection of the required flange rating was discussed in MEX 101.04. Type of flange face, such as raised face (RF), ring joint (RTJ), or flat face (FF). Flange face requirements were discussed in MEX 101.04. Flange material specification and grade, such as A-105; A-350, Grade LF-2. Flange material selection was discussed in MEX 101.04 and MEX 101.08. Fitting rating, such as Sch. 40 for butt-weldtype fittings, or 3,000 lb. for threaded- or socket-welded-type fittings. The rating of pipe fittings was discussed in MEX 101.04 and MEX 101.08. Fitting material specification and grade, such as A-105; A-234, Gr. WPB. Fitting material specification was discussed in MEX 101.04 and MEX 101.08. Any specific remarks with regard to material,
11.
12.
13.
14.
15.
16.
12
components, system limitations. Include items such as the following: Precautions that are necessary during operation or tests. For example, the need to blind-off expansion joints during hydrostatic tests because they will not withstand the test pressure, or the need to add temporary supports during hydrotest. Special piping components that may be in the system, such as soft-seat ball valves.
Operating Limits (Entries 17-28) 17. & 18. Indicate the MAOP and temperature for the lines as one system based on its weakest point, such as the corrosion condition of the line, pressure vessels, flanges, etc. MAOP was discussed in MEX 101.03 and MEX 101.04. 19. Enter the actual new test pressure. The test pressure should be consistent with the hydrostatic test diagram and SAES-A-004. Test pressure requirements were discussed in MEX 101.09.
13
Operating Limits, (Entries 17-28), Cont'd 20. Show the limiting item for the test pressure, such as flanges, pipewall thickness, pressure vessel, heat exchanger. Enter the design pressure, which should be consistent with SAES-L-002. Enter the design temperature, which should be consistent with SAES-L-002. Indicate the limiting item for the design pressure, such as pipewall thickness, flanges, process limitations, or any other limiting item. Enter the equipment safety valve set pressure, not greater than that shown under Key Number 21. Nominal Pipe Size (NPS). Note that there are three columns for size and for Key Numbers 26 and 27. This permits providing information about three separate pipe sizes that may be within the same piping system. Required minimum wall thickness, tm, for the pipe. Refer to ASME/ANSI B31.3 and MEX 101.03 for method of calculation. Note that tm is the retirement wall thickness, and shall also not be less than the required wall thickness for mechanical strength. Refer to Saudi Aramco Inspection Procedure 01-AIP-02-0, SAESL-006, or the piping specialist in the Consulting Services Department, for further explanation. When tm is for mechanical strength, indicate this in the remarks section. 27. This is calculated based on the nominal wall thickness of the pipe, minus manufacturing undertolerance for thickness, and minus the
21. 22. 23.
24.
25.
26.
14
value that was determined for Key Number 26. Note that the corrosion allowance, c, as determined here, is the remaining pipewall thickness that is above the required tm. 'c' is not the required corrosion allowance that was specified as part of the initial design conditions for the piping system. If a corrosion allowance is required, it must be stated in the remarks area under Key Number 28. 28. Add any remarks that pertain to any item or calculation above. Indicate any items or hazards which require consideration by operations, inspection or maintenance personnel.
15
Miscellaneous Information (Entries 29-35) 29. 30. 31. 32. 33. 34. District and location. Plant number. Follow the usual procedure to obtain drawing numbers. Include BI and JO under which the equipment was installed. Complete this section showing date and name of originator. Engineering concurrence as indicated in Section 4 of this standard plus project manager or plant manager's approval, as required. Signature of Facility Engineering Division head.
35.
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FORM 2821
FIGURE 1
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WORK AID 2:
PROCEDURES FOR DETERMINING THE INFORMATION TO COMPLETE A SAFETY INSTRUCTION SHEET FOR CROSSCOUNTRY PIPELINES Saudi Aramco Form 5645-1 Use the following procedure in conjunction with Figure 2 to determine the information that is necessary to complete Safety Instruction Sheet, Form 5645-1, for pipelines. The identification numbers that are shown in the following procedure correspond to those shown in Figure 2. Reference SAES-A-005, Safety Instruction Sheet, for additional information. Note that by the time it is necessary to complete Form 5645-1, engineering has been completed, all of the required information is readily available, and no new calculations or selections are needed.
Work Aid 2A:
Pipeline Identification (Entries 1-12) 1. Give the official designation of the pipeline, e.g., "Qatif-Ras Tanura Pipeline Number 6" (QRT-6) and indicate the fluid that is being handled, such as "stabilized Arabian Light Crude," "fuel gas," or "water." Show the name of the pipeline origin, such as "Qatif Junction." Show the name of the pipeline termination point, such as "Ras Tanura." Indicate the type of fluid that is being handled, such as Arab Light. Show the name of the valve operating diagram of this line, such as "NACRUDE." If not available, give the P & ID Drawing Number. Indicate the year in which the line was built.
2. 3. 4. 5.
6.
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7. 8.
Give the Kilometer Number where the pipeline begins. Give the Kilometer Number of the pipeline where this particular sheet begins. A pipeline will typically require several Forms 5645-1 to cover its entire length. This entry defines where this particular sheet starts. Show the number of sheets which cover all major segments of the pipeline to be covered by Form 5645-1. This entry defines how many sheets are used for the entire pipeline.
9.
Pipeline Identification (Entries 1-12), Cont'd 10. & 11. Enter the number of the sheet(s) that cover items which will be covered by Form 5645-2, as identified above. 12. Segments of the pipeline are to be numbered sequentially, i.e., Sheet 1 will show Segments 1-5, Sheet 2 will show Segments 6-10, and so on. A single pipeline will have multiple segments. Note that each segment shall have the same diameter, wall thickness, material grade, hydrostatic test pressure, MAOP, Area Classification, and type of construction. If any of these characteristics change, a new Segment Number is to be used. Also, the portion of the pipeline that is located between any two major facilities (such as a scraper trap, pump station, or a junction point) shall be considered as a separate segment even if it has the same characteristics as an adjacent segment.
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Equipment Data (Entries 13-24) 13. 14. 15. Nominal or outside diameter. Nominal wall thickness, with fractions shown in decimals. Show the grade of pipe material, such as API 5L, GR. X50. SAMSSs references are not acceptable. Enter the starting kilometer location of the segment. Enter the ending kilometer of the segment. Indicate the length of the segment, in feet, as shown on the layout drawing. Since the actual routing of the pipe will not necessarily be straight between kilometer stations, the length of the pipeline segment is not simply the difference between the two kilometer markers. Indicate the length of the segment in kilometers.
16. 17. 18.
19.
20
Equipment Data (Entries 13-24), Cont'd 20. Seamless (S). Longitudinally (straight seam) welded submerged-arc (Electricfusion welded) by U-ing, O-ing, Expanding (UOE-EFW). Longitudinally (straight seam) welded submerged-arc (Electricfusion welded) by Cage Forming (CF-EFW). Longitudinally (straight seam) welded electric-resistancewelded (UOE-ERW), (CF-ERW). Special-welded, submerged-arc (Spiral-EFW). 21. Indicate the Specified Minimum Yield Strength in psi, as shown on the mill certificates, for each item of the purchase order. For example, 41,000 psi. Indicate the flange rating per ASME/ANSI B16.5. Selection of the flange rating was discussed in MEX 101.04. Show the type of construction for the pipeline segment as follows: 24. B: Buried Show the process of manufacture for the pipe (see the mill inspection report).
22.
23.
AGR: Restrained Aboveground. AGN: Nonrestrained Aboveground.
Include any remarks that are related to pipe material, such as "X65 pipe in Segment 3 is installed on an experimental basis to check weldability".
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Operating Limits (Entries 25-40) 25. Calculate the internal pressure that is required to develop a hoop stress that is equal to the Design Factor (DF) multiplied by the Specified Minimum Yield Strength (SMYS) of the pipe based on the pipe outside diameter (OD) and nominal wall thickness (Tn). MAOP = (DF)(SMYS)(2Tn)/(OD) If other factors are limiting (such as flange rating), indicate the lower MAOP and annotate accordingly. MAOP of a pipe section was discussed in MEX 101.03. 26. Indicate the limiting factor of the MAOP, and whether it is the pipewall thickness or any other factor, such as flange rating. Show the Design Factor of the segment, such as 0.5, 0.6, or 0.72. Design Factor was discussed in MEX 101.03. Show the maximum design temperature. Indicate minimum design tie-in temperatures specified in the project specification or "scope of work". Indicate the allowable bending stress, Sb, per SAES-L-051 and SADP-L-051. Allowable bending stress was discussed in MEX 101.07. Calculate the required minimum wall thickness of the pipe, Tm, based on the segment MAOP and the Design Factor, DF. The required minimum wall thickness of the pipe was discussed in MEX 101.03. Tm = (MAOP)(OD) / [2(DF)(SMYS)] Note that Tm is the retirement wall thickness, and shall not be less than the required wall
Saudi Aramco DeskTop Standards 22
27.
28. 29.
30.
31.
thickness for mechanical strength. Refer to Saudi Aramco Inspection Procedure 01-AIP02-0, SAES-L-006, or to the piping specialist in the Consulting Services Department for further explanation. 32. Show the actual hydrostatic test pressure of the particular segment of pipeline that is performed immediately after construction. The test pressure must be calculated in accordance with SAES-A-004, Pressure Testing. Test pressure requirements were discussed in MEX 101.09.
Operating Limits (Entries 25-40), Cont'd 33. 34. Show the test date. Indicate the factor that limits the test pressure, such as pipewall thickness, flange rating, branch connection, etc. Note that entries for revalidation hydrostatic tests (entries 35-37) are to be completed when the information is known. The Safety Instruction Sheet (SIS) is to be updated after every revalidation test by the responsible Operations Engineering unit. 35. Indicate the actual test pressure for the revalidation test. The test pressure shall be in accordance with SAES-A-004 and approved by the responsible Saudi Aramco Engineering unit. Show the test date. Indicate the factor that limits the test pressure. Note that this does not necessarily have to be the same item that limited the initial hydrotest pressure. For example, the original hydrotest pressure might have been limited by the flanges. However, corrosion which may have occurred in the pipe, itself, could make it the
36. 37.
23
limiting component for a revalidation test. 38. Indicate the Maximum Allowable Operating Pressure (MAOP) of the entire pipeline as if one system, if applicable. This MAOP will be dictated by the lowest of the MAOP's across the entire pipeline, or the maximum pressure that is achievable upstream due to, for instance, well head or pump shutoff pressure. If the pipeline does not have one MAOP for the system, indicate this by "N/A" and give a clear explanation in the remarks area, such as "the line is telescoped." Show the limiting factor that dictates the system MAOP. Include any pertinent remarks that will assist operations, inspection or maintenance personnel. Any safety hazards for the pipeline or fluid that is transported should be mentioned. If the pipeline is constructed such that the pipe, flanges, valves, or fittings will not withstand the shutoff pressure of the pump plus the static head pressure when a downstream valve is closed, then this hazard must be clearly highlighted. Indicate if surge protection system(s) have been provided. Make reference to any special operating instructions.
39. 40.
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Miscellaneous Information (Entries 41-48) 41. Include the drawing numbers of schematic layout, P & I diagram, process flow diagram, hydrostatic test diagram, and hydraulic profile drawing. District and/or location and the official pipeline name, as in Item #1. Show the Plant No. Follow the usual procedure to obtain a drawing number. Include BI and JO under which the pipeline was installed. Complete this section showing the date prepared and the name of the originator. Engineering concurrence as indicated in Section 4 plus Project Manager or Plant Manager's approval, as required. Signature of Facility Engineering Division head.
42. 43. 44. 45. 46. 47.
48.
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FORM 5645-1
FIGURE 2
26
Work Aid 2B - Saudi Aramco Form 5645-2 Use the following procedure in conjunction with Figure 3 to determine the information that is necessary to complete Safety Instruction Sheet, Form 5645-2, for pipeline tie-in piping, scraper traps and their appurtenances, jumpovers, as well as flanges, fittings, any special components, road crossings, sun-pressure relief valves, flowlines, trunklines, testlines, and submarine pipelines. The identification numbers that are shown in the following procedure correspond to those shown in Figure 3. Reference SAES-A-005, Safety Instruction Sheet, for additional information. Note that by the time it is necessary to complete Form 5645-2, engineering has been completed, all the required information is readily available, and no new calculations or selections are needed. Pipeline Identification (Entries 1-9) 1.-6. 7. Same as corresponding Key Numbers 1-6 on Form 5645-1. Provide adequate information to clearly identify the equipment; for example, scraper trap, block valve MOV-123, etc. Show the location of the equipment by name and kilometer, such as Qatif Junction, km. 0.0. In the case of flowlines, testlines, or trunklines, show the GOSP name at which these lines terminate. This section number corresponds to a numbering system that is adopted in the pipeline data book. Therefore, this information must be coordinated with the proponent.
8.
9.
27
Equipment Data (Entries 10-20) 10. Show the nominal or outside pipe diameter. List each kind (one diameter, wall thickness and steel grade) of pipe or fitting once in separate columns. Show the nominal wall thickness of pipe, fractions in decimals. Show the material, such as carbon steel, alloy, etc. Indicate the process of manufacture for the pipe, such as seamless (S) or EFW, ERW, or spiral. Show the pipe material specification and grade, such as API 5L, Gr. B. SAMSSs references are not acceptable.
11. 12. 13.
14.
Equipment Data (Entries 10-20), Cont'd 15. 16. Show the nominal size of flanges and fittings. Enter the rating per ASME/ANSI B16.5 for flanges and valves. Selection of the flange rating was discussed in MEX 101.04. Enter the type of flange face, such as raised face (RF) or ring joint (RTJ). Flange facing was discussed in MEX 101.04. Enter whether carbon steel or alloy is used for flanges or fittings. Specify the ASTM or other specification and grade of the material used for flanges or fittings. List any special piping components that are not otherwise covered, and include any other pertinent remarks.
17.
18. 19.
20.
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Operating Limits (Entries 21-37) 21. Calculate the Maximum Allowable Operating Pressure (MAOP) in accordance with the applicable code, as limited by flanges or by the nominal pipewall thickness, for materials that are listed under Key Numbers 10 through 20. MAOP was discussed in MEX 101.03 and MEX 101.04 for pipe and flanges, respectively. Show the item that is limiting the MAOP in Key Number 21. Show the Design Factor, and give the basis of the Design Factor in the remarks area in Key Number 37. The Design Factor was discussed in MEX 101.03. Show the design temperature. Show the actual hydrostatic test pressure of this particular equipment item that was performed immediately after construction. The test pressure must be calculated in accordance with SAES-A-004, Pressure Testing. Test pressure requirements were discussed in MEX 101.09. The test pressure of this equipment item must be equal to or greater than the test pressure in Key Number 32, Form 5645-1, for the pipeline segment to which this equipment is connected. Show the test date.
22. 23.
24. 25.
26.
Operating Limits (Entries 21-37), Cont'd 27. Indicate the item (pipeline segment, flange or special fitting) which limits the test pressure. Note that entries for revalidation of hydrostatic tests (entries 28-30) are to be completed when the information is known. The Safety Instruction Sheet (SIS) is to be updated after every revalidation test by the responsible
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Operations Engineering unit. 28. Indicate the actual test pressure for the revalidation test, which must be in accordance with SAES-A-004 and approved by the responsible Saudi Aramco Operations Engineering unit. The test pressure of this equipment must be equal to or greater than the test pressure in Key Number 35, on Form 5645-1, for the segment to which this equipment is connected. Show the test date. Indicate the factor that limits the test pressure. Note that this does not necessarily have to be the same item that limited the initial hydrotest pressure. For example, the original hydrotest pressure might have been limited by the flanges. However, corrosion which may have occurred in the pipe, itself, could make it the limiting component for a revalidation test. Indicate the Maximum Allowable Operating Pressure (MAOP) of the entire pipeline as if one system. This MAOP is the same as that in Key Number 38 on Form 5645-1. In case of flowlines, testlines, or trunklines, refer to SADP-L-022 for further information. 32. Show the limiting item for the system MAOP. In the case where a Saudi Aramco standard governs, indicate which standard it is and its date, such as SADP-L-022, 30 August 1985. Show the set pressure of the safety valve, sunpressure relief valve, pressure switch, or other safety device if one is included, and if it is required for routine operation. Confirm this information with the P & ID. Enter the nominal size or outside diameter.
29. 30.
31.
33.
34.
30
Operating Limits (Entries 21-37), Cont'd 35. Calculate Tm based on the system MAOP that is shown in Key Number 31. If not applicable, use the MAOP in Key Number 21. Note that Tm is the retirement wall thickness, and shall not be less than the required wall thickness for mechanical strength. Refer to Saudi Aramco Inspection Procedures 01-AIP02-0, SAES-L-006, or to the piping specialist in the Consulting Services Department, for further explanation. 36. Calculate the corrosion allowance (Tca) which equals the nominal wall thickness of the pipe minus Tm that is shown in Key Number 35. Note that the corrosion allowance, Tca, is the remaining pipewall thickness that is above the required Tm. This is not a required corrosion allowance. If a corrosion allowance is required, it must be stated (including the referenced standard) in the remarks area under Key Number 37. 37. Include any special remarks regarding safety hazards in connection with items on the subject sheet. See the remarks for the main line pipe, Form 5645-1, Key Number 40.
Miscellaneous Information (Entries 38-45) 38. Indicate specific drawings for the manifolds, crossovers, branches, scraper traps, road crossings, and any items that are covered by this sheet. Show the district, area or location, and the official pipeline, or the equipment name, as shown in Key Number 1. Enter the plant number.
31
39.
40.
41. 42. 43. 44.
Follow the usual procedure to obtain a drawing number. Include the BI and JO under which the pipeline/equipment was installed or revised. Complete this section showing the date prepared and name of the originator. Engineering concurrence as indicated in Section 4, plus Project Manager or Plant Manager's approval, as required. Signature of the Facility Engineering Division head.
45.
32
FORM 5645-2
FIGURE 3
33
GLOSSARY
AGN AGR CF EFW FF NPS RF RTJ Saudi Aramco Form 2821 Saudi Aramco Form 5645-1 Saudi Aramco test Form 5645-2 and SMYS UOE
Nonrestrained Aboveground Restrained Aboveground Cage Forming Electric-Fusion Welded Flat-Face Flange Nominal Pipe Size Raised-Face Flange Ring-Joint Flange A Safety Instruction Sheet for Plant Piping A Safety Instruction Sheet for Cross-Country Pipelines A Safety Instruction Sheet for flowlines, trunk lines, lines, submarine pipelines, tie-in piping, scraper traps their appurtenances, and special components. Specified Minimum Yield Strength U-ing, O-ing, Expanding
34

Safety Instruction Sheets For Plant Piping and Cross-Country Pipelines

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