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Engineering Procedure

SAEP-35 27 November 2014


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

Saudi Aramco DeskTop Standards


Table of Contents

1 Introduction..................................................... 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Safety Precaution……......………….……….... 3
5 Handling and Hauling…..................…………. 3
6 Receiving Inspection...…................…………. 4
7 Hydrotest Requirement...................…………. 4
8 Preparation and Test Procedures....……...…. 5
9 Storage Area Requirement…………....……... 6
10 Storage Procedures...…………………..…….. 6
11 Long Term Store Requirement…………....…. 6

Previous Issue: 25 December 2010 Next Planned Update: 27 November 2019


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Primary contact: Al-Jarallah, Bader Mohammed (jarallbm) - on +966-13-8809621

Copyright©Saudi Aramco 2014. All rights reserved.


Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

1 Introduction

1.1 Purpose

The purpose of this procedure is to establish guidelines for valves supply


process to insure their continuous reliability and to preserve their quality
throughout the whole process of transportation, receipt, testing and storage.

1.2 Scope

This procedure is intended only to provide general guidelines for valve handling,
hauling, receipt, testing and storage.

It shall be noted that this document is intended as a guideline and minimum


requirements only, as it may not cover all possible variations and combinations
of specific valve type. Manufacturers may have extra requirements as deemed
necessary. In case of conflicts between these guidelines and the manufacturer’s
instructions, Valves Standards Committee Chairman (VSCC) shall be consulted.

2 Conflicts and Deviations

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

3 References

The requirements contained in the following documents apply to the extent specified in
this procedure:

3.1 Saudi Aramco References

Saudi Aramco Engineering Standard


SAES-A-004 General Requirements for Pressure Testing

Saudi Aramco Materials System Specifications


04-SAMSS-035 General Requirements for Valves
04-SAMSS-048 Valve Inspection and Testing Requirements

Saudi Aramco Inspection Checklists


SAIC-A-2009 Verification of Test Preparation and Test Equipment

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Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

for Pressure Testing


SAIC-A-2015 Visual Inspection of Pressure Test
SAIC-A-2017 Depressurization & Disposal of Hydrotest Water
SAIC-L-2040 Receiving Inspection of Manual Valves
SAIC-L-2041 Storage and Preservation of Valves
SAIC-L-2042 Field Hydrostatic Testing of Isolation Valves

Saudi Aramco General Instructions


GI-0002.102 Pressure Testing Safely
GI-0007.030 Inspection and Testing Requirements for
Elevating/Lifting Equipment

4 Safety Precautions

Certain precautionary steps must be addressed clearly and adhered to prior to and
during the performance of Hydrostatic Testing of valves and transportation such as, but
not limited to the following:
i) Prior to starting any Hydrotest activities, all requirement of GI-0002.102 shall be
fulfilled.
ii) Personnel involved with the testing and inspection shall competent to perform the
required task.
iii) Use only designated lift lugs for lifting.
iv) Tools must be inspected to be fit for service, including sling wires and tie
connection. All requirement of GI-0007.030 shall be fulfilled.
v) Never try to open or make repairs to any pressurized part of the valve before
depressurizing and verifying no trapped pressure exists.
vi) Work area must be prepared; accessibility must be fully provided for safe testing
and inspection.

5 Handling and Hauling

5.1 Appropriate and consideration shall be taken during handling and transporting of
valves against mechanical damages.

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

5.3 All valves shall comply with 04-SAMSS-035 shipment preparation requirement

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Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

during transportation, handling and field storing at all times.

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

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

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

5.7 Valve to be lifted through the manufacturer designated lift points.


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

5.8 Valves are to be transported in the manufacturer’s recommended open/closed


position.

6 Receiving Inspection

Receiving inspection shall be performed prior to transfer of custody to insure no


damage has occurred during transportation and handling, and it shall be conducted
within 10 days from valve receipt at site. A standard inspection checklist SAIC-L-2040
can be used. The following points shall be verified:
i) Confirm no visible signs of transportation damage.
ii) Check the integrity of the caps, external fitting and other visible conditions.
iii) Verify the end covers are intact and no dirt or sand has entered the valve body.
iv) Confirm the valve is still in the full open\closed position per the Original
Equipment Manufacturer “OEM”.
v) Verify that all hydrotest water has been drained and the machined area is coated
with a light film of high viscosity rust inhibiting oil.
Note: Secure the end covers and repack immediately after conducting of the receiving
inspections.

7 Hydrotest Requirement

Hydrostatic tests shall be carried as per below requirements. Standard inspection


checklist SAIC-L-2042 Field Hydrostatic Testing of Isolation Valves can be used as a
base.
Note: Prior to starting any Hydrotest activities, fulfilled all requirements of GI-0002.102.

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Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

7.1 Test Location

The site location shall be evaluated and approved by Inspection Department


through a formal assessment. The test location conditions shall be maintained
throughout the testing period. The following requirements shall be considered:
a) The location/shop: The location should have means of protections against
introduction of foreign matters such as dirt/sand or other hard particles.
Note: During site testing, the weather conditions must be taken into consideration.

b) Valves fixtures: Valves should be supported off the ground and restrained
from any free movement.
c) Floor profile: Flooring shall be hard such as concrete floor, paving or any
sort tiling.
d) Accessibility: Work area must be prepared and accessibility must be
provided for inspection

7.2 Testing Equipment Capability


a) Blinds: they shall be matching with the same rating and type of the valve
ends. Both blinds shall be provided with pressure/vent connections.
b) Blind/bolts conditions: They must be clean and shall not have signs of
corrosion.
c) Pressure gauges: the test pressure shall not be less than 30% no greater
than 80% of the full scale range of the pressure gauge. All instruments
shall have the calibration certificates.
d) All connections must have the proper pressure ratings.
e) The pressure reliefs and their setting must comply with SAES-A-004.

7.3 Test Fluid

The fluid quality shall be within the acceptable criteria of 04-SAMSS-048.

7.4 Test Procedure

The following requirements need to be available in order to perform the


hydrostatic testing:

7.4.1 Prior to commencing the testing, a test procedure shall be developed in


accordance with 04-SAMSS-048, SAIC-A-2009, SAIC-A-2015,
SAIC-A-2017 andSAIC-L-2042.

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Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

7.4.2 Manufacturer instructions and guidelines shall be taken into consideration.

7.4.3 The procedures shall address the following as minimum requirement:


i) The set pressures for hydrostatic shell test and/or seat test.
ii) Test durations.
iii) Acceptable leakage rates.
iv) Sequence of testing.
v) Stabilization periods.
vi) Monitoring procedures.
vii) If the valve is equipped with Double-Piston Effect (DPE) feature,
the procedure shall include steps to test this seat configuration.
viii) Draining, drying procedures: The procedure shall specify the
draining, dewatering procedure. The methods to remove all test
medium residuals and the required insurance measures.
ix) Corrosion prevention, upon completion of drying process, means of
corrosion inhibition and lubrication shall be applied as applicable.
The machined surfaces shall be coated with a light film of high
viscosity rust inhibiting oil which will not become fluid and run off
at temperatures below 80°C.
x) If the valve is equipped with sealant injectors, inject a sufficient
amount of light lubricant in order to push out any remaining moisture
in the seat pocket area and replace it with the fresh lubricant.
xi) Upon completion of the testing, valves shall be restored to the
original packing condition if installation time is not immediately
after the testing as per 04-SAMSS-035 and/or SAIC-L-2041.

8 Storage Area Requirements

8.1 Storage area shall be assessed and approved by Inspection department.

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

8.3 Valves shall not be laid directly on ground; means of supporting off ground shall
be provided such as wooden pallets, shelves, timber bases, ….etc.

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Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

9 Valves Storing Procedures

9.1 Prior to storage, valves shall be inspected for proper packaging and protection.
SAIC-L-2041 can be utilized as a base.

9.2 Valves shall be stored in the manufacturer’s recommended positions and


orientation.

9.3 Manufacturer’s long term storage procedures shall be considered.

9.4 For packaging of unpacked valves please refer to 04-SAMSS-035 or


SAIC-L-2041.

10 Long Term Store Inspections

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

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

10.3 Prior to cycling, long term stored valves shall be topped up with new lubricants.
Note: Any storage for a period of three months and longer shall be considered as
long term store.

11 Records and Traceability

11.1 Records established to provide evidence of conformity to requirements


addressed in this procedure shall be controlled. Records shall remain legible,
readily identifiable and retrievable

11.2 For better traceability, it is recommended to adapt a tagging system for valves.
The following could be considered:
i. Tags to be introduced during the receiving inspection and maintained by
assigned inspectors until valve installation.
ii. It is recommended to include a check point for each step including
receiving inspection, site hydrostatic testing, packing and storage.
ii. The tag should also include the valve information, inspector name and the
date of each activates.
iv. Tags shall be of a weather prove material such as vinyl and shall be
securely attached to the valve body; Nylon quick strap can be used.

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Document Responsibility: Valves Standards Committee SAEP-35
Issue Date: 27 November 2014
Next Planned Update: 27 November 2019 Valves Handling, Hauling, Receipt Tests and Storage

v. Color tags could be utilized for better indications for the valve acceptance
(i.e., green: accepted, red: rejected, blue: hold). The utilization of color
spray in the valve body is unacceptable practice.

Revision Summary
27 November 2014 Revised the Next Planned Update, reaffirmed the content of the document, and reissued
as major revision.

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