SHUTDOWN & TIE-IN PROCEDURE

MAINTAIN POTENTIAL PROJECTS

Saad Al-Essa Group

Trading and Contracting

Shutdown &TIE-IN PROCEDURE SDGM-1005

(S_TIE-IN-SAG-04, Rev 0)

PIPELINE AND INDUSTRIAL SERVICES DIVISION

P.O. Box 126 Dammam Code 31992
Kingdom of Saudi Arabia

BI-10-01277-6497

SDGM 1075 WELL TIE-IN TO SDGM-1005

CONTRACT # 6600038900 (SA-1)

Saudi Aramco Maintain Potential

Projects

S_TIE-IN-SAG-04, Rev 0 1
 SHUTDOWN & TIE-IN PROCEDURE
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SHUTDOWN & TIE-IN PROCEDURE OF

SDGM-1075 TO SDGM-1005

PREPARED BY:
Saad Al-Essa Group
Trading and Contracting

S_TIE-IN- Issue for

SAG-4, Rev 0 0 22-11-2017
Approval
QA/QC QA/QC SAGPD
SAPMT
Mechanical Manager Engineer

REV. Recommended
Date Description Prepared: Reviewed: Approved
PRO. NO. # Approval

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CONTENTS

1. GENERAL SCOPE

2. OBJECTIVES

3. REFERRENCE DRAWINGS

4. STANDARDS/G.I

5. SAFETY PRECAUTIONS

6. WARNING

7. TOOLS AND EQUIPMENTS REQUIRED FOR TIE-IN

8. TIE-IN PROCEDURE

9. COLD CUT PROCEDURE

10. REVALIDATION TEST PLAN

11. TIE-IN POINT IDENTIFICATION

12. RESPONSIBILITIES

13. ATTACHMENTS

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1.0 GENERAL SCOPE

Saudi Aramco Standards the Purpose of this procedure is to covers the requirement to perform
the TIE-IN of:

1. 6”x 0.500 WT (TEE) with 4”-P-0104-15CS9P API 5LX60 SMLS Externally Coated pipe
line to existing line from SDGM-1005,OPTF & TIE-IN area (TIE-IN # 007)
2. 2”x 0.218 WT ASTM A312 TYPE 316L SS pipe line 2”-BD-0125-15SD0P with existing
line from SDGM-1005,OPTF & TIE-IN area by cold cut.(TIE-IN#008)

2.0 OBJECTIVES

The objective of this procedure is to conduct the tie-in of these facilities in a safe manner, to
prevent damage and destruction of properties and to ensure the downtime of the system is kept
to minimum according to the scope of Work Section and shut down Tie-in.

3.0 REFERENCES DRAWINGS

 BA-989602-006 PIPING AND INSTRUMENTATION DIAGRAM

 BA-989629-003 HYDROSTATIC TEST DIAGRAM
 BB-989663-001 ISOMETRIC PIPING DETAIL
 BB-989650-001 ISOMETRIC PIPING DETAIL

4.0 STANDARDS / GI
G.I.2.100, Work Permit System
G.I.2.708, Gas Testing Procedure
G.I.441.0441,Installation of Balloon and Mud Pack
 SAES-L-105, Piping Material Specifications
 SAES-L-109, Selection of Flanges, Stud Bolts and Gaskets.
 SAES-L-350, Construction of Plant Piping.
 SAEP-351, Bolted Flange Joints Assembly.
 ASME B16.20, Metallic Gaskets for Pipe Flanges- Ring-Joint, Spiral-Wound, and
Jacketed.
 ASME B16.21, Nonmetallic Flat Gaskets for Pipe Flanges.
 ASME B16.5, Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24.
 ASME B16.47, Large Diameter Steel Flanges NPS 26 through NPS 60.
 MSS SP-44, Steel Pipe Line Flanges.
SAES-W-012, Welding Requirements for Pipelines
SAES-A-005, Safety Instruction Sheet
SAES-A-004, General Requirements for pressure Testing

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5.0 SAFETY PRECAUTIONS

The Following safety precautions should be observed during the isolation of Valves/piping
and tie-in

 Shutdown of the existing facilities shall be scheduled by Saudi Aramco representative

and shall be informed of shutdown dates as early as possible, so that contractor can
schedule the activities for the shutdown and execute the work to minimize shutdown
duration.
 Shutdown and tie-in will be carried out strictly in accordance with Aramco standard
and specifications to the operation inspection group, and CTS recommendations.
 A copy of the approved procedure is to be kept at site prior to start, shutdown and tie-
in. The Superintendent In-Charge must obtain all required work permits Adequate
Warning sign both in English and Arabic shall be provided in the vicinity of the job
site.
 Before starting the work, ensure that all warning and safety signs are erected. All
warning barriers, sign and lights, installed shall remain in position until the completion
of the works.
 Prior to starting the shutdown and tie-in works, the person who is responsible for
coordinating shall hold a meeting at job site to review the procedure and safety
requirements, safety section representative shall be informed to attend the meeting for
the said purpose.
 Only personnel involved in the shutdown and tie-in will be allowed to remain on site
 Fire Extinguishers shall be place adjacent to the work sites as back up in cases of
emergency.
 All materials required are on site prior to start shutdown and tie-ins.
 Pipe and fittings to be tie in or isolated should be bonded before tools are applied to the
pipes and or fittings. It should be noted that section of pipe due for removal or isolation,
should be bonded before the second tie-in is attempted. The cable should be sufficient
length so as not interfere with the work hand
 Care shall be taken to channel the oily water, away from the work site to a collection pit
where it can be transferred away at the earliest possible time
 Welders should be qualified and certified by Saudi Aramco.
 Great care must be taken to ensure that the positive conduction is established b/w all
points of contact of the bonding cable to the pie metal.it is recommended that this be
achieved with the use of metal straps around the pipe at each side of the proposed tie-in
and existing pipes
 Care should be taken to channel all water away from the work site to a collection pit
where it should be transferred away at the earliest possible time
 Saudi Aramco or designated representative shall conduct combustible gas test and
inspection before and during the commencement of work

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6.0 WARNING

 It needs but a minute source of ignition to produce a velocity explosion, which will
multiply throughout the length of the pipe and beyond its source
 “Short-cut”to any of these procedures will quickly develop a hazardous situation
 Always recognize the invisible presence of static electricity inherent in steel pipe,
unless the bonding wire is efficiently conducted
 All equipment should be well maintained and capable of achieving the duration of the
work
 All bolts must secure for their Tightness
 It is essential that a meeting of all personnel on site be established to ensure there is
discipline during the procedure and all the safety requirements are adhered to
 Upon Successful completion, remove all temporary materials tools and equipment from
the vicinity

7.0 TOOLS AND EQUIPMENT REQUIRED FOR TIE-IN

The following equipment and tools should be at each job site before commencement of the
work

 Gas monitor (T40/Tester)

 Fire Extinguishers
 Mobile air compressor
 Welding machine
 Bonding Cable
 Water Tankers
 Magnetic spirit level
 Fillet gauges
 Dial indicator
 Pipe jack stands
 Chain block/ puller
 Feeler gauge
 Bevel gauge
 Hi-lo Gauge
 Fork Lift
 PPEs

Representative of operations should be at the work site at all times to monitor gas releases
with 3 in 1 gas tester which is in good working condition. All management on site should
monitor the gas tester readings to ensure that gas release is within safe working limits.

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8.0 TIE-IN PROCEDURE

FOR TIE-IN M24-007(4”-P-0104-15CS9P TO EXISTING FLOW LINE FROM SDGM-1005

 Operation shall shut down the existing line from SDGM-1005. Make sure that there is
zero pressure and clean the line.
 Line 4”-P-0104-15CS9P shall be connected to the 6”x4” reducer pipe and tee pipe
6”x0.500”WT prior to flange connection in existing line from SDGM-1005,OPTF &
TIE-IN area..
 Before start of the flange connection, make sure that there is no traces of gasses remain
in the existing line.
 A release permit shall be taken to start the work. Confirms the type and pressure rating
of the mating flanges with the IFC drawings and line class for piping. Clean the flange
face specially the seated area and make sure that gasket contact area is not coated (To
ensure proper contact surface for sealing purpose).
 Measure the rotation of flanges as the offset between elevations of bolt holes on opposite
sides of a flange centerline, shall not exceed ± 2.4 mm. The tilt of a flange measured at
the periphery across any diameter shall not exceed 1.6 mm from the square position.
(SAES-L-350, Para.9.4 c&d). Bolts, nuts and washers shall be visually checked for
proper size, grade, and dimension and for any physical damage to shanks or threads
which would affect the bolt assembly or performance, Use SAEP-351Apendix C for
joint alignment requirement. Check the suitability of the stud bolts and nuts material for
the service temperature and the compatibility with the flange material.
 Hammering/flogging and impact wrench is not permitted during bolts losing and
tightening. Tightening tools shall be checked for adequacy, performance and calibration.
 Bolt tightening sequence shall be as per SAEP-351 appendix E. Torque values shall be
determined according to flange rating, bolt size, type of gasket and lubricant friction
factor

FOR TIE-IN M24-008 (2”-BD-0125-15SD0P TO 2”EXISTING BLOW DOWN LINE)

 Operation shall shut down the existing 2” blow down line and make sure that there is
zero pressure and the line is clean before starting demolition of the existing spools.
 A release permit shall be taken to cut the existing blow down line.
 Existing blow down line shall be flushed and cut at the tie-in location (provided by
operation) along with the installation of the new blow down piping (BB-989663-001)
 Revalidation for the blow down line shall be done for the new blow down line
(revalidation test pressure and UT reading to be done and given by operations)

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9.0 COLD CUT PROCEDURE

Item Activity Description Responsibility
No
Secure necessary work permit from UTMN Khuff gas
01 CONTR./PMT
field Services operation
Sandblast and perform UT reading on the tie-in points to OPERATION
02
ensure sufficient wall thickness for welding INSPECTION
UTMN Operations shall do the initial shutdown ISOLATE
03 DRAIN and Flush the existing blow down line by cold PROPONENT
cut.(TIE-IN#8A & 8B)
Prior to cold cutting bonding cable shall be installed;3
meters away from both sides of the cutting area across the
pipe section to be cold cut (refer to SAEP-310,para-3.2.2).
Bridging the section to be removed, ensuring a positive
04 CONTR/PMT
conduction is established between the cable and pipe. The
cable should be of sufficient length so as not to interfere
with work in hands. It is important that the bonding cable
is not removed during the lifting of the cut off pipeline.
Prior to cold cutting, wind direction shall be established
and ensure that the crew is situated upwind of the cut
location. Make sure the Sufficient cutting machines (With
spare wheels/blades), Scott air packs/Gas stoppers, and
water coolant spray for cutting machine and fire
05 extinguishers are must be available on site. The air CONTR/PMT
compressor and other equipment to be used should be in
good working condition and shop run tested prior to
delivery to site
Safety accessories like goggles, gloves, safety hats and
shoes should be worn during cutting.
During the cutting, ones the pipe has been pierced, the
machine should be stopped and the pipe examined to
OPERATION
06 establish if there are excessive releases of
CONTRACTOR
gas/hydrocarbons. Work should not recommence until it is
deemed safe to do so by proponent
During the cold cutting process the cutting blades of the
07 hacksaw shall be cooled continuously with an adequate PMT/CONTRACTOR
supply of water
During unbolting and cutting, checks shall be made to
08 ensure that the water from the pipe is being channeled PMT/CONTRACTOR
away to the nearest drain pit
During cutting ,checks shall be made also to ensure that
09 PMT/CONTRACTOR
the pipe is correctly and adequately supported to avoid it

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from sudden movement could cause damage to the

machine and injure personnel
When the cut is completed, discarded pipe section should
be removed slowly ensuring the bonding cable is in place.
10 PMT/CONTRACTOR
The cut-out section should be placed away from tie-in
point location
Gas/Leak test should be made to ensure it is gas free prior
11 PMT/CONTRACTOR
to welding
During welding random gas check shall be done PROPONENT
12
CONTRACTOR
Upon completion of welding 100% radiography shall be
CONTRACTOR
13 taken and the result should be given to Saudi Aramco
INSPECTION
inspector

NOTE:
Operations shall make sure that there is no more pressure inside the line and well is
safe for the contractor to start work.

10.0 REVALIDATION TEST PLAN

(2”-BD-0125-15SD0P TO 2”EXISTING BLOW DOWN LINE) REFERENCE DRAWING #

BA-989602-006

 This revalidation test is for the existing lines in 2” existing blow down line new line from
SDGM-1075 and in between the nearest flange ball valve and the nearest flange at the new
Tie-In on scraper area.
 The actual test pressure shall be determined using U.T Reading by Saudi Aramco
 All piping must be cleaned & flushed with air or water to ensure the line is clean of all sand,
dirt or construction debris to inspection satisfaction prior to filling with hydrostatic test fluid
 Install temporary blind flange fit with water fill connection on the existing flange near the well
head. Temporary vent valve and pressure gauge connection shall be provided at the tie-in point
of the converted header & Scraper Area,
 Provide necessary blinds, Plugs before revalidation test the line.
 After isolating the lines, install the hydrostatic test manifold connection at the fill point and
start filling the system with hydrostatic test fluid. Vent out entrapped air while water filling at
the system.
 After the system is filled-up with the hydro test water and packed, a 24 hours decaying period
shall be allowed (whenever necessary) in order to achieve temperature equilibrium.
 The line system is ready, begin pressurization test gradually; hold to allow time for material to
strain @ 50% strength test pressure for checking any leaks. If no leaks found, continue &

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increase in step no greater than 1/5th (20%) of the strength test pressure at least 10 minutes hold
at each increased pressure.

Note:
 Depressurize the system to zero “0” pressure before attempting to stop or to repair
any leaks.

 Upon reaching the required test pressure, close valve and disconnect the hydrostatic test pump
and maintain the pressure as long as required by the inspection personnel
 Upon successful completion, depressurized the system slowly to zero psig. remove all
temporary blinds & test equipment and dewater the system
 Put back the line in to stream
 Site clean-up

11.0 TIE-IN POINTS IDENTIFICATION

JOB ORDER NO#10-01277-6497

TIE-IN NO. DESCRIPTION DRAWING NO

M24-007 4”-P-0104-15CS9P TO EXISTING FLOW LINE BA-989602-006-00

FROM SDGM-1005 BA-989650-001-00

M24-008 2”-BD-0125-15SD0P TO 2”EXISTING BLOW BB-989663-001-00

DOWN LINE FROM SDGM-1005 BA-989602-006-00

NOTE: PMT & CONTRACTOR SAFETY OFFICIRES MUST BE AT JOB SITE DURING TIE-IN
PERIOD.

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SHUTDOWN MANPOWER EQUIPMENT CHART

PROJECT/SITE
ENGINEER

QA/QC SAFETY
SUPERVISOR SUPERVISOR

FOREMAN FIRST AID

CREW WITH
AMBULANCE

OPERATOR

PIPE FITER

WELDER

HELPER

DRIVER

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12.0 RESPONSIBILITIES.
Site Manager has the responsibility for overall the project activities including safety
measures
QC Manager Ensure all required documents are approved and available. Point of contact
in case of problems related to QA/QC. Ensure the quality documents are distributed for
effective implementation
Site Engineer shall be responsible for obtaining work permits and ensures all ITPs are
coordinated according to safety and quality requirements and for the compliance with all
standards, specifications and codes. Additionally provide technical support.
QC Inspector shall be responsible for inspection and monitoring of the work and ensure
that the work is performed and properly documented in accordance with approved ITPs,
method statement, project requirements
HSE Supervisor Shall be directly involved in the planning and executions of the activities.
HSE plan must be implemented and observed during work. Safety officer shall be present
on site at all times during activities.

13.0 ATTACHMENT

 BA-989602-006 PIPING AND INSTRUMENTATION DIAGRAM

 BA-989629-003 HYDROSTATIC TEST DIAGRAM
 BB-989663-001 ISOMETRIC PIPING DETAIL
 BB-989650-001 ISOMETRIC PIPING DETAIL

Site Superintendent
OMPPD/GUPD/SDGM

Concurred:

Supervisor
SDGM KGM OPERATION

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