Inspection Requirements

SAER-1972 Introduction to the Saudi Aramco Inspection Requirements Document Responsibility: Inspection Dept. 30 September 2000

Saudi Aramco DeskTop Standards

Table of Contents Preface................................................................ Introduction......................................................... Scope.................................................................. SA-175 Form/CCC Categorization...................... Column Activities................................................. Line Activities...................................................... Acceptance Criteria............................................. Metrication Policy................................................ Inspection Codes................................................ Packaged and Skid Mounted Equipment............ Special SA-175 Inspection Requirement Forms. Inspection Reports.............................................. Additions to SAER-1972...................................... Changes to the Coded SA-175 Forms.............. Routing................................................................ Approval.............................................................. Availability of Coded SA-175 Forms...................
Previous Issue: New Next Planned Update: TBD Revised paragraphs are indicated in the right margin Document Responsibility: Inspection Dept. For additional information, contact Ahmed S. Al-Khater on 873-8933

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

Completion of SA-175 Form P.O. Information Block........................................... 8

Preface The critical nature of Saudi Aramco's projects and operations mandates a cost effective quality assurance / quality control program for purchased materials and equipment. The SA-175 forms Inspection Requirements were developed to promote this by consolidating the inspection and test requirements of mandatory Saudi Aramco Engineering Standards. This form is to be used to specify the minimum required quality certification and verification for the purchase of all inspectable engineered materials and equipment. The Form SA-175 is flexible and unique requirements may be added, if necessary, by preparing and including a Form SA-175 "Special" in the requisition package. These SA-175-Forms are reviewed and revised periodically to reflect Saudi Aramco's requirements. If you need to cover additional equipment or correct an error, please fax or write to the address given below. Vendor Inspection Division Engineering Building E-1340 A Dhahran 31311 Saudi Arabia Attention: Superintendent, Vendor Inspection Division

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

Introduction

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

The purpose of defining the "Inspection Requirements" through the Form SA-175 is to consolidate all inspection requirements as defined in the Company's standards and specifications. The "Inspector" is a Saudi Aramco, ASC or AOC Inspection representative, a Saudi Aramco contracted inspector, or a Saudi Aramco prime contractor inspector. The "Buyer" is a Saudi Aramco, ASC or AOC Purchasing representative, or a Saudi Aramco prime contractor buyer. Scope SAER-1972 contains coded SA-175 forms, indicating the inspection and testing requirements for inspectable items purchased by or on behalf of Saudi Aramco. Form SA-175 provides the Supplier and/or Manufacturer with a summary of Saudi Aramco inspection and witnessing requirements for its use during fabrication of the material or equipment. At the same time, it provides the Inspector with a list of the minimum required activities. The type of activity is indicated by an "X" in one of the three columns provided on the form. In case of conflict between the SA-175 form and a SAMSS, the SAMSS is the governing document. SA-175 Form/CCC Categorization The existing CCCs were categorized into (A, B, or C). Based on this, SA-175 forms were developed for category (A and B). The description of each category is as follows: Cat A: Visual inspection required (some Xs exist in column 1 and/or 2 of the SA-175 form), Certificates required (some Xs exist in column 3 of the SA-175 form), Coded or special SA-175 form is needed, and initial Plant approval and periodic assessments are required. Certificates required only (some Xs exist in column 3 of the SA-175 form), Coded or special SA-175 form is needed, and initial Plant approval and periodic assessments are required. Initial Plant approval and periodic assessments are required. Commodity (CCC) is not inspectable at the plant. No SA-175 form needed.

Cat B:

Cat C:

Column Activities The headings of the columns and their meanings are as indicated below: 1. Visual inspection/witnessing by the Buyers Representative (column 1):

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

An "X" in this column indicates a hold point for the Inspector to verify Manufacturer/Supplier's compliance in the listed line activity and the Manufacturer/Supplier shall not proceed beyond any hold point until a written release is issued by the Inspector. Supplier/Manufacturer shall notify the Inspector a minimum of 5 working days in advance of the hold point. If visual inspection is waived, the Manufacturer shall send the required certificates to the responsible Saudi Aramco, ASC, or AOC Inspection Office for review and acceptance. Visual inspection may only be waived when specified by the responsible Saudi Aramco, ASC, or AOC Inspection office. Only Saudi Aramco prime contractor or his designated independent third party inspector shall schedule and perform source inspection at supplier and major sub-supplier fabrication sites in accordance with the SA-175 form requirements. 2. Certificates/records to be checked by the Buyers Representative (column 2): An "X" in this column indicates that: a) The Inspector will verify the quality records for compliance with the specifications at the Manufacturers or sub- Contractors plant prior to accepting the material. The records may include material test reports, quality control procedures, non-destructive examination (NDE) records, radiographs, weld procedure specifications (WPS), procedure qualification records (PQR) and welder qualification records (WQR), etc. The Manufacturer shall provide the required quality records to the Inspector for review.

b) 3.

Certificates/data to be provided by Vendor / Supplier / Manufacturer (column 3): An "X" in this column indicates that the Inspector is to review the certificates, data and/or test reports for compliance to the specifications prior to accepting the material and forward copies with the Inspection Report to the Buyer. All inspection certificates/test reports shall be in duplicate, in English, using foot-pound or SI system of measurement, and shall reference Saudi Aramco P.O. & L/I numbers. Manufacturer shall not ship material prior to issuance of a release note by the responsible Inspection Office.

4.

Specification Details/Notes:

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

This column provides detailed inspection procedures, test methods, acceptance criteria, exceptions, verifications, and additional specific requirements. Line Activities The explanation of the line activities stated on the SA-175 form is given below: 1. Pre-Fabrication / Pre-Production Requirements: The Manufacturer shall ensure that incoming product is not used or processed until it has been inspected or otherwise verified as conforming to specific requirements in accordance with the quality plan and/or documented procedures. 2. In-Process Inspection & Testing Requirements: The Manufacturer shall: a) b) 3. Inspect and test the product as required by the approved quality plan and/or documented procedures. Hold product until the required inspection and tests have been completed or necessary reports have been received and verified.

Final Inspection & Testing Requirements: The Manufacturer shall carry out all final inspection and testing in accordance with the approved quality plan and/or documented procedures to complete the evidence of conformance of the finished product to the specified requirements. No product shall be dispatched until all the activities specified in the quality plan and/or documented procedures have been satisfactorily completed and the associated data and documentation are available and authorized.

4.

Additional/Supplementary Requirements: Tests and/or inspection requirements which apply only when the condition is stated in the purchase order description, attached drawings / data sheets or referenced specifications.

A line activity with no "X" in any of the three columns 1, 2 or 3 is not a requirement. Condition Statements - These are line activities that contain the phrase only if and apply only when the condition is stated in the purchase order description, attached drawings/data sheets or referenced specifications. The use of these conditional statements makes it necessary for the purchase requisition originator / end user to consider the condition and make a statement about that condition in the body of the requisition if it applies.

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

If the Purchase Order does not address the condition in the body of the Purchase Order, then the Inspector and Manufacturer / Supplier will ignore the requirement. Some conditional statements are in the NOTES at the bottom of the SA-175 form. Acceptance Criteria The criteria for acceptance or rejection after completion of an inspection/test activity is governed by the applicable purchase specifications. Deviations from the purchase specification; require written approval by the Buyer before they can be accepted by the Inspector. The inspector should notify the responsible Saudi Aramco, ASC or AOC Inspection office of such discrepancies for further review and action by the Vendor Inspection Division. Metrication Policy Saudi Aramco's metrication policy is covered by SAEP-103. During the transition period, certificates, charts, records etc. provided by the Supplier may be in conventional units unless specified otherwise in the SAMSS, project specifications, drawings, or Purchase Order. Inspection Codes The codes of SA-175 forms identify different forms for inspectable material and equipment. The first two digits of the code refer to the class of material in the Saudi Aramco Material System. The other four digits are control numbers used by Inspection. The coded SA-175 forms are arranged sequentially. The inspection code number is also entered into the cataloging database and printed on the computer generated stock requisitions to indicate the required inspection action. PATIS will accept for electronic transmittal only the coded SA-175 Forms. Forms SA-175 "Special" generated by the requisition originator must be transmitted in hard copy and must be reviewed and endorsed by the Saudi Aramco, ASC or AOC Inspection office. Any alteration to a standard coded SA-175 Form changes the form to a SA-175 "Special" which must be transmitted in hard copy. Packaged and Skid Mounted Equipment Form SA-175 provides sufficient space and flexibility to accommodate all types of equipment. However, it is not normally designed to cover more than one kind of equipment. For packaged and skid mounted equipment, separate forms are required for each type of inspectable equipments in addition to the SA-175 Special to cover the inspection and testing of the assembled Packaged And Skid Mounted Equipment. As an example: For an electric motor driven centrifugal compressor, SA-175 forms are required for compressor (s), gear(s), heat-exchanger (s), pumps (s), valve (s) etc.
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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

Special SA-175 Inspection Requirement Forms Purchase requisition originators may specify source inspection requirements for materials, which are not covered by coded SA-175 forms, by filling in the blank SA-175-Form and typing "Special" under "CODE NO". Purchase requisition originators may also modify the content of the coded SA-175 Forms by typing "Special" in the "CODE NO." field for individual purchase orders provided the following procedure is followed: 1. If the modification involves a waiver of an inspection activity specified in Saudi Aramco Engineering Requirements (See SAEP-301), a waiver shall be duly obtained per SAEP-302 before altering the SA-175 form. If the modification is to delete or add an inspection activity not explicitly stated in Saudi Aramco Engineering requirements (see SAEP-301) such as witnessed tests, certification requirements etc., which are indicated in the coded SA-175 Form, a letter or fax of concurrence shall be obtained from the responsible Saudi Aramco, ASC or AOC Inspection office before altering the SA-175-Form.

2.

The Vendor Inspection Division shall be consulted for all queries on the "Special" SA-175 Forms. Inspection Reports All the activities and inspections performed at the Supplier's plant will be recorded in Inspection Reports by the Inspector and shall be made available to the Buyer when requested. The record of inspections is to be maintained by the Saudi Aramco, ASC, or AOC Inspection office for a minimum of 5 years after the date of inspection completion. Additions to SAER- 1972 New SA-175 Forms to cover inspection requirements of Saudi Aramco Material System Specifications (SAMSS) are to be prepared and sent to the Superintendent, Vendor Inspection Division for review and approval prior to inclusion in SAER1972. Changes to the Coded SA-175 Forms Proposals for changing the contents of coded SA-175 Forms shall be sent to the address shown in the PREFACE. Routing New SA-175 Forms and change proposals to existing SA-175 forms are checked for compliance to applicable standards and sent to the RSA's and Inspection Offices for review and concurrence.

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Document Responsibility: Inspection Dept. Issue Date: 1 December 1996 Next Update: TBD

SAEP-1972 Introduction to the Saudi Aramco Inspection Requirements

If a proposed change is in conflict with existing standards, the originator of the change is advised. Approval The final formatted and coded SA-175 Form is approved by the Superintendent, Vendor Inspection Division, Saudi Aramco, for inclusion in the SAER-1972. Availability of Coded SA-175 Forms Coded SA-175 Forms are available on the Standards-On-Line (SOL) System and will be attached by the Buyer when identified in the requisition or when the inspection code is contained in the SAMS description. Coded SA-175 forms and index are also available in the on-line/CD Desktop Standards and Company INTRANET under Inspection Requirements. On an emergency basis, requirements for hard copy of SA-175 Forms may be addressed to: Supervisor, Technical Information Center, E-3100, Dhahran. Completion of SA-175 Form P.O. Information Block The P.O. number, line item applicability, page Number and date are required to be entered by the requisition originator on all SA-175 Forms coded "Special". This information may be omitted on the standard coded SA-175 Forms, however the relevant inspection code and revision date must be shown on the Requisition/P.O.

Revision Summary 30 September, 2000 Major revision.

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