Engineering Standard

SAES-L-125 10 July 2019

Safety Instruction Sheet for Piping and Pipelines
Document Responsibility: Piping Standards Committee

Contents
1 Scope ..................................................................... 2
2 Conflicts and Deviations ......................................... 2
3 References ............................................................. 2
4 Definitions .............................................................. 3
5 Purpose .................................................................. 3
6 Preparation ............................................................. 4
7 Approval ................................................................. 6
8 Control .................................................................... 6
Revision Summary ........................................................ 6

Attachment A-1 – Completion of Form SA-2821,

Critical Plant Piping ................................................ 7
Attachment A-2 – Completion of Form SA-5645-1,
Cross Country Pipelines - Main Line Pipe .............. 9
Attachment A-3 – Completion of Form SA-5645-2,
Cross-Country Pipelines - Critical Piping .............. 13
Attachment A-4 – Completion of Form SA-5645-3,
Safety Instruction Sheet - Terminal and
Bulk Plant Piping .................................................. 17

Previous Issue: 16 February 2017 Next Planned Update: 31 August 2021

Revised paragraphs are indicated in the right margin Page 1 of 22
Contact: Muslim, Husain M. (musallhm) on phone +966-13-8804667

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

1 Scope

This standard specifies mandatory requirements and outlines the procedure to be

followed in the preparation of Safety Instruction Sheets (SIS) for piping and pipeline
systems for new facilities, or additions to existing facilities.

2 Conflicts and Deviations

2.1 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.

2.2 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.

3 References

The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-122 Project Records
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-202 Saudi Aramco Engineering Drawing Preparation
SAES-B-061 Protective Shields for High Health Hazard Piping
and Equipment
SAES-L-100 Applicable Codes and Standards for Pressure
Piping Systems
SAES-L-105 Piping Line Classes
SAES-L-150 Pressure Testing of Plant Piping and Pipelines
SAES-L-310 Design of Plant Piping
SAES-L-410 Design of Pipelines

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

SAES-L-450 Construction of On-land and Near Shore Pipelines

SAES-L-850 Design of Submarine Pipelines and Risers

Saudi Aramco Forms and Data Sheets

SA-2821 Safety Instruction Sheet - Critical Plant Piping
SA-5645-1 Safety Instruction Sheet for Cross Country Pipelines
- Main Line Pipe
SA-5645-2 Safety Instruction Sheet for Cross Country Pipelines
- Critical Piping
SA-5645-3 Safety Instruction Sheet - Terminal and Bulk Plant
Piping
SA-5645-4 Safety Instruction Sheet - Nonmetallic Pipelines

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B31.3 Process Piping
ASME B31.4 Liquid Transportation Systems for Hydrocarbons,
Liquid Petroleum Gas, Anhydrous Ammonia and
Alcohols
ASME B31.8 Gas Transmission and Distribution Piping Systems

4 Definitions

Definitions in the referenced Saudi Aramco standards are applicable to this standard.

5 Purpose

5.1 The purpose of safety instruction sheets is to ensure that operations, engineering,
maintenance, and inspection personnel are provided with adequate information
in a consistent format concerning safe operating limits, protective devices and
any special safety precautions for all piping systems and pipelines.

5.2 Safety Instruction Sheets shall be prepared for all piping which in view of size,
pressure rating, and application are within the scope of Saudi Aramco
Engineering Standards and general industry codes referred to therein, including:
a) Critical plant piping as defined in SAES-L-100.
b) Cross country and offshore pipelines within the scope of SAES-L-100,

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

SAES-L-410, and SAES-L-850.

c) Terminal and bulk plant piping that is considered critical as defined in
SAES-L-100.
d) Onshore and offshore oil/gas field pipelines including flowlines,
trunklines, water injection, and supply lines.

5.3 Safety Instruction Sheets shall reflect the as built information. They may be
completed during the project design stage, however all information shall be field
verified.

6 Preparation

Safety Instruction Sheets for Piping are prepared for new piping systems or
additions/modifications to existing piping systems as follows:

6.1 The following Saudi Aramco Engineering Forms are available for completion of
SIS. Detailed guidelines listing the key numbers to complete these forms have
been prepared and are shown as attachments.
a) Saudi Aramco Form SA-2821, Safety Instruction Sheet - Plant Piping, see
Attachment A-1. Refer to paragraph 6.2.
b) Saudi Aramco SA-5645-1, Safety Instruction Sheet for Cross Country
Pipelines - Main line Pipe, see Attachment A-2, Section A. Refer to
paragraph 6.3.
c) Saudi Aramco SA-5645-2, Safety Instruction Sheet for Cross Country
Pipelines - Critical Piping, see Attachment A-3, Section B. Refer to
paragraph 6.3.
d) Saudi Aramco SA-5645-3, Safety Instruction Sheet - Terminal and Bulk
Plant Piping, see Attachment A-4. Refer to paragraph 6.4.

6.2 Form SA-2821 “Safety Instruction Sheet - Plant Piping” shall be prepared for
plant piping which is critical because:
a) Its failure leads to a major shutdown of the plant or a major unit in the plant,
b) Its failure leads to a major reduction in throughput of the plant,
c) Its failure leads to a major environmental impact,
d) High temperature [340°C (650°F) or higher],
e) High pressure [3,450 kPa (500 psi) or greater],
f) Hydrocarbon at or above its auto ignition point (450°F or above),
g) Fluid released could result in gas cloud and explosion,

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

h) Toxic or corrosive nature of fluid handled (as defined in SAES-B-061),

i) General hydrocarbon fluid lighter that diesel at ambient temperature or
diesel at or above 225°F.

For review purposes, the issuer of the form is to attach a calculation sheet with
each form. The calculation sheet shall show, in detail, the method for achieving
calculated values (formulas, individual variables in the formulas with their units,
specific standards requirements, etc.).

6.3 Form SA-5645-1, “Safety Instruction Sheet for Cross Country Pipelines -
Main Line Piping” shall be completed for all major pipelines, trunklines, and
cross country pipelines, in general, carrying any fluid. Flowlines are excluded.

In addition, Form SA-5645-2, “Safety Instruction Sheet for Cross Country

Pipelines - Critical Piping” shall be filled out for the same pipelines to cover tie-
in piping, scraper traps and their appurtenances, jumpovers, as well as flanges,
fittings or any special components.

Both forms (SA-5645-1 and SA-5645-2) are to retain the same Saudi Aramco
drawing number, but with different sheet numbers. For review purposes, the
issuer of the forms is to attach a calculation sheet with each form. The calculation
sheet shall show, in detail, the method for achieving calculated values in
accordance with the applicable Code ASME B31.3, ASME B31.4, or ASME B31.8
(formulas, individual variables in the formulas with their units, specific standards
requirements, etc.).

6.4 Form SA-5645-2, “Safety Instruction Sheet for Cross Country Pipelines -
Critical Piping” shall be prepared for flowlines, trunklines, testlines, submarine
pipelines and those critical components within a pipeline network, e.g., lateral
ins, lateral outs, station by-passes, lateral intermediate traps, launcher/receiver
barrels, fill lines, gas meter stations, etc.

6.5 Form SA-5645-3, Safety Instruction Sheet - Terminal and Bulk Plant Piping
shall be prepared for all piping in Terminals and Bulk Plants that is considered
to be critical as defined in SAES-L-100. A calculation sheet shall be attached to
each SIS showing the method for achieving calculated values in accordance with
the applicable Code ASME B31.3, ASME B31.4, or ASME B31.8 (formulas,
individual variables in the formulas with their units, specific standards
requirements, etc.). In addition, a diagram showing the limits of each piping
section covered by the SIS is to be attached. The calculation sheet and diagram
are to retain the same Saudi Aramco drawing number as the SIS sheet, but with
sheet numbers 002 and 003, respectively.

6.6 Form SA-5645-4, “Safety Instruction Sheet for Nonmetallic Pipelines” shall be
prepared for onshore and offshore flowlines, trunklines, testlines, water injection

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

and supply lines. For review purposes, the issuer of the form is to attach a
calculation sheet with each form. The calculation sheet shall show, in detail, the
method for achieving calculated values (formulas, individual variables in the
formulas with their units, specific standards requirements, etc.).

7 Approval

Safety Instruction Sheets are considered as Key Engineering Drawings. Therefore, they
are to be handled per Section 10 of SAES-A-202.

In general, the Project Manager is responsible for the preparation, approval and issue of
the Safety Instruction Sheets on new construction projects. When piping is installed or
modified outside a new construction project scope, the Facility Engineering Division
Head is responsible for SIS preparation and approval.

Copies of the Safety Instruction Sheets and the applicable design data sheets may be
submitted to the Manager, Consulting Services Department for review and concurrence
by his designated representative(s) where CSD expertise is required. Revised Safety
Instruction Sheets shall be issued where necessary as a result of this review.

8 Control

Safety Instruction Sheets shall be assigned Saudi Aramco drawing numbers and shall
become a part of the Project Photostat Book, Section A, and Project Inspection Record
Books. These SI Sheets shall be submitted to the proponent as per SAEP-122.

Revision Summary
22 February 2012 Revised the “Next Planned Update”. Reaffirmed the contents of the document, and reissued
with no other changes.
16 February 2017 Major revision to add new SIS tailored for nonmetallic flowlines in hydrocarbon and water
service and revising existing SIS to include Post Weld Heat Treatment (PWHT) requirement
(YES/NO).
10 July 2019 Editorial revision to “Conflicts and Deviations” to be in line with the Technical Deviation
Approvals of SAEP-302, removed unnecessary references, and changed the Next Planned
Update to 31 August 2021.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

Attachment A-1 – Completion of Form SA-2821, Critical Plant Piping

Complete this form as required in paragraph 6.2 of this standard.

A blank form with key numbers is included at the end of this attachment, and an
electronic file in Excel format is also available in the Forms and Data Sheets section of
Saudi Aramco Desktop Standards.

LINE IDENTIFICATION (ENTRIES 1-6)

1 Show line designation and specification: e.g., P- 28-3A1, P-102-3CS9P, etc.
Indicate where line starts and ends, e.g., Furnace F-201 to Column C-221, Acid
2 &3
pumps G-21A/B to Reactor D-21.
4 Give specific data on fluid; e.g., Reduced Crude with Acid, Vapor, etc.
5 Show applicable Industry Code and year, e.g., ASME B31.3, '90.
Pertinent pipe isometrics, P & ID's, Line Designation Table, or other reference
6
drawings.
EQUIPMENT DATA (Entries 7-22)
7 Enter nominal pipe size - in inches
8 Enter pipe outside diameter – in inches
9 Enter pipe wall thickness – in inches
10 Indicate material specification, e.g., A-106, API 5L, etc.
11 Indicate material grade, e.g., Gr.B, X-42, etc.
12 Enter basic allowable stress at design temperature (from Table A1, ASME B.31.3)
13 Indicate welded (SAW) or seamless (SMLS).
14 Indicate weld joint quality factor (Ej), obtained from Table 302.3.4 of ASME B31.3.
15 Enter flange rating according to ASME B16.5.
16 Indicate if the flanges are raised face (RF), ring joint (RJ), or flat face (FF), etc.
17 Indicate material specification, e.g., A-105, A-350, etc.
18 Indicate material grade, e.g., LF-2, etc.
19 Indicate fitting rating, i.e., Sch. 40, 3000 lb., etc.
20 Indicate material specification and grade, e.g., A-105, A-234, API 5L, etc.
21 Indicate material grade, e.g., WPB, X-42, etc.
Indicate any specific remarks regarding material. Include precautions necessary
22 during operation of tests, such as need to blind off expansion joints during
hydrostatic tests because they will not withstand the test pressure.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

OPERATING LIMITS (Entries 23-33)

23 Enter the design pressure, which should be consistent with SAES-L-310.
24 Enter the design temperature, which should be consistent with SAES-L-310.
Indicate the limiting item, e.g., pipe wall, flanges, process limitations, or any other
25
limiting factors.
Enter the actual test pressure when the line was new (i.e., immediately after
26 construction). The test pressure shall be in accordance with SAES-L-150 and
should be consistent with the hydrostatic test diagram and SAES-A-004.
Show the limiting item of the test pressure, such as flanges, pipe wall thickness,
27
vessel, exchanger, etc.
28 Equipment safety valve setting not greater than that shown under key number 23.
Calculated required minimum wall thickness (Tm) at which the pipe can withstand
29 an internal pressure equal to the internal design pressure without exceeding the
allowable stress based on ASME B31.3.
30 Indicate the Required Corrosion Allowance (Tca). If not required, enter N/R.
This is the sum of line 29 and 30. This is the Required Minimum Thickness per
31
ASME B31.3 (Tm + Tca).
If the minimum pipe thickness for mechanical strength (per Table I in SAES-L-310)
is greater than the calculated required minimum thickness listed on line 29, enter
32
that minimum pipe thickness. Otherwise, leave it blank. Refer to SAES-L-310 or
the Piping Specialist in Consulting Services Department for further explanation.
Remarks pertaining to any item or calculation above. Indicate any items or hazards
33
which require consideration by Operations, Inspection or Maintenance.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

Attachment A-2 – Completion of Form SA-5645-1,

Cross Country Pipelines - Main Line Pipe

Complete this form as required in paragraph 6.3 of this standard.

A blank form with key numbers is included at the end of this attachment, and an
electronic file in Excel format is also available in the Forms and Data Sheets section of
Saudi Aramco Desktop Standards.
GENERAL
Pipelines Department has established a comprehensive database for all of its pipelines.
Refer to this database for information and data of existing pipelines. This database can
be obtained from Pipelines Department, Pipelines Technical Support Division, R-238,
Building 3301, NP-II, Dhahran (Tel. 874-1460, Fax 874-1331).

LINE IDENTIFICATION (ENTRIES 1-11)

1 Give the official designation of the line, e.g., “Qatif-Ras Tanura Pipeline No. 6”
(QRT-6).
2 Show name of start (origin) point, e.g., “Qatif Junction”.
3 Show name of end (termination) point, e.g., “Ras Tanura”.
4 Indicate the type of fluid handled, e.g., “Arab Light Crude”, or “Fuel Gas” or “Water”
5 Show the name of the Valve Operating Diagram of this line, e.g., NACRUDE.
If not available, give the P & ID drawing number.
6 Indicate the year in which the line was built.
7 Give the Km. number where the line begins.
8 Give the Km. number of the line where this particular sheet begins.
9 Show number of sheets which cover all major segments of the pipeline to be
covered by Form SA-5645-1, then followed by:
10 The number of the sheet(s) that cover the items which will be covered by Form
SA-5645-2, as identified above.
11 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.
NOTE: Each segment shall have 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 is to be generated.
EQUIPMENT DATA (Entries 12-24)
12 Enter the nominal diameter of pipe.
13 Enter nominal wall thickness (Tn). Fraction of an inch should be express to
3 decimal places, e.g., “0.375 inches”.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

14 Show the grade of material, i.e., API 5L, Gr.X-50. SAMSS references are not
acceptable.
15 Indicate Starting Km. of the segment.
16 Indicate Ending Km. of the segment.
17 Indicate the length of the segment in feet.
18 Indicate the length of the segment in meters.
19 Show process (see mill inspection report) for line pipe: Seamless (S);
Longitudinally (straight seam) welded-submerged arc (Electric Fusion Welded) by
U-ing, O-ing, Expanding (UOE-EFW); Longitudinally (straight seam) welded-
submerged arc (Electric Fusion Welded) by Cage Forming (CF-EFW).
Longitudinally (straight seam) welded-electric resistance Welded (UOE-ERW),
(CF-ERW); Special welded – Submerged Arc (Spiral-EFW).
20 Indicate the minimum Specified Minimum Yield Strength (SMYS) in psi, shown on
the mill certificates for each item of the Purchase Order, e.g., 41,300 psi.
21 Indicate the flange rating per ASME B16.5.
22 Show the type of construction: B: Buried, AGR: restrained above ground,
or AGN: non-restrained above ground.
23 Indicate if the line is externally and/or internally coated and what type of coating
as applicable.
24 Include any remarks on pipe material, such as “X-65 pipe in segment 3 is installed
on experimental basis to check weldability”.
OPERATING LIMITS (Entries 25-43)
25 Calculate internal pressure to develop a hoop stress equal to the Design Factor
(D.F.) multiplied by the Specified Minimum Yield Strength (SMYS) of the pipe
based on OD and corroded wall thickness (Tc), which equals Tn - Tca.
P= (D.F.) * (SMYS) * (2*Tc)/(OD)
If other factors are limiting (for example flange rating) indicate the lower MAOP
and annotate accordingly.
26 Indicate the limiting factor of the MAOP whether it is the pipe wall or any other
factor such as flange rating.
27 Show the design factor of the segment, e.g., 0.5, 0.6, or 0.72.
28 Show the maximum design temperature (°F).
29 Indicate minimum design tie-in temperatures (°F) specified in the project
specification or “Scope of Work”.
30 Indicate the allowable bending stress (Sb) per SAES-L-450.
31 Calculate the required minimum wall thickness (Tm) of the pipe based on the

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

MAOP for the entire pipeline and the design factor (D.F.).
Tm= (MAOP) * (OD) / [2*( D.F.* SMYS)]
Commentary Note:
Tm (retirement wall thickness) shall not be less than the required wall thickness
for mechanical strength. Refer to SAES-L-410 or piping specialist in the
Consulting Services Department for further explanation.
32 Show the actual hydrostatic test pressure of that particular segment performed
immediately after construction. The test pressure must be calculated in
accordance with SAES-L-150 “Pressure Testing”.
Commentary Note:
Consideration should be given to the increased head due to elevation differences
within the test segment. If this is significant, the low point test pressure must be
indicated with a remark.
33 Show test date.
34 Indicate the limiting factor of the test pressure, e.g., pipe wall thickness, flange
rating, branch connection, etc.
Commentary Note:
Revalidation hydrostatic tests (Entries 35-37) are to be completed when
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. The test pressure shall be in accordance with
SAES-L-150, SAES-A-004 and approved by the responsible Saudi Aramco
Operations Engineering Unit.
36 Show test date.
37 Indicate the limiting factor of the test pressure.
38 Indicate the date of the baseline run using instrument scraping.
39 Indicate the date of the latest run.
40 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 achievable pressure upstream
due to, for instance, well head or pump shut off pressure. If the pipeline does not
have one system MAOP, indicate so by “N/A” and give a clear explanation in the
remarks area, such as 'the line is telescoped'.
41 Show the limiting factor that dictates the system MAOP.
42 List any pertinent remarks which will assist Operations, Inspection or Maintenance.
Any safety hazards for line or fluid transported should be mentioned. If the pipeline
is constructed such that the pipe, flanges, valves, or fittings will not withstand the
shut-off 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 systems(s) have been provided. Make reference to
any special operating instructions.
43 Include drawing numbers of Schematic Lay-out, P & I Diagram, Process Flow
Diagram, Hydrostatic Test Diagram, and Hydraulic Profile Drawing.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

Attachment A-3 – Completion of Form SA-5645-2,

Cross-Country Pipelines - Critical Piping

This form shall be prepared as required per paragraph 6.4 of this standard.

A blank form with key numbers is included at the end of this attachment, and an
electronic file in Excel format is also available in the Forms and Data Sheets section of
Saudi Aramco Desktop Standards.
Commentary Note:

Some of the information may not be applicable in cases where the form is used for above
ground unrestrained pipelines, such as flowlines.

LINE IDENTIFICATION (ENTRIES 1-10)

1-6 Same as corresponding key numbers 1-6 on Form SA-5645-1.
7 Provide adequate information to clearly identify the equipment, for example,
scraper trap, block valve MOV-123, etc.
8 Show the location of the equipment by name and kilometer, e.g., Qatif Junction,
Km. 0.0. In the case of flowlines, testlines, or trunklines, show the GOSP name at
which these lines terminate.
9 This section number corresponds to a numbering system adopted in the Pipeline
Data Book, therefore, this information must be coordinated with the proponent.
10 Indicate Equipment Category, e.g., Scraper Receiver” or “Jumpover” or “Lateral” or
“Crossover”, etc.
EQUIPMENT DATA (Entries 11-21)
11 Show nominal or outside pipe diameter. List each kind (one diameter, wall
thickness and steel grade) of pipe or fitting once in separate columns.
12 Show nominal wall thickness of pipe. Fractions of an inch should be expressed to
3 decimal places, e.g., “0.375 inches”.
13 Show material, carbon steel, alloy, etc.
14 Indicate seamless (S) or EFW or ERW or Spiral.
15 Show pipe specification and grade, e.g., API 5L, Gr. B. SAMSS references are not
acceptable.
16 Indicate if the line is externally coated and what type of coating as applicable.
17 Indicate flange or fitting rating, e.g., ASME B16.5 for flanges and valves, etc.
18 Enter a two letter abbreviation indicating the type of flange facing, e.g., RF for
raised face, RJ for ring joint, etc.
19 Show material, carbon steel or alloy used.
20 ASTM or other specification and grade for flanges or fittings

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

21 List any special piping components not otherwise covered and include any
pertinent remarks.
OPERATING LIMITS (Entries 22-39)
22 Calculate maximum allowable operating pressure (MAOP) in accordance with
applicable code as limited by flanges or by nominal pipe wall for materials listed
under key numbers 10 through 20. Show the item that is limiting the MAOP in key
number 21.
23 Show the design factor, and give the basis of the design factor in the remarks area
in key number 37.
24 Show the design temperature (°F).
25 Show the actual hydrostatic test pressure of this particular equipment performed
immediately after construction. The test pressure must be calculated in
accordance with SAES-L-150. The test pressure of this equipment must be equal
to or greater than the test pressure in key number 32 on Form SA-5645-1, for the
segment to which this equipment is connected.
26 Show test date.
27 Indicate the item (pipeline segment, flange or special fitting) which limits the test
pressure.
Revalidation Hydrostatic Tests (Entries 28-30) are to be completed when
information is known. The Safety Instruction Sheet (SIS) is to be updated after
every revalidation test by the responsible Operations Engineering Unit.
28 Indicate the actual test pressure which must be in accordance with SAES-L-150
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 SA-5645-1, for the segment to which this
equipment is connected.
29 Show test date.
30 Indicate the limiting factor for the test pressure.
31 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 40 on
Form SA-5645-1.
Commentary Note:
In the case of flowlines, testlines, and trunklines, refer to SAES-L-410 for
further information.

32 Show the limiting item. In the case where a Saudi Aramco Standard governs,
indicate which standard it is and its date.
33 Show the set pressure of safety valve or thermal relief valve or pressure switch or
other safety device if included, and if required for routine operation. Show relief
device identification number, e.g., “PZV-123”, etc. Confirm this information with the
P&ID.
34 Show nominal pipe size.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

35 Calculate Tm based on the system MAOP shown in key number 31. If not
applicable, use the MAOP in key number 22.
Commentary Note:
Tm (retirement wall thickness) shall not be less than the required wall
thickness for mechanical strength. Refer to SAES-L-310 or SAES-L-410 or
piping specialist in the Consulting Services Department for further
explanation.

36 Calculate the available corrosion allowance (Tca) which equals the nominal wall
thickness of pipe minus Tm shown in key number 35.

Commentary Note:
Corrosion allowance (Tca) is the remaining pipe wall thickness 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 38.

37 Indicate On-Stream Inspection Data.

Commentary Note:
This data is entered into Pipelines Department database by a web
application and the program automatically displays the available information.
It is not normally entered manually.

38 Indicate any special remarks regarding safety hazards in connection with items on
subject sheet. See remarks for main line pipe, Form SA-5645-1 key number 42.
39 Indicate specific drawings for the manifolds, cross-overs, branches, scraper traps,
road crossings, and any other items covered by this sheet.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

Attachment A-4 – Completion of Form SA-5645-3,

Safety Instruction Sheet - Terminal and Bulk Plant Piping

Complete this form as required in paragraph 6.5 of this standard.

A blank form with key numbers is included at the end of this attachment, and an
electronic file in Excel format is also available in the Forms and Data Sheets section of
Saudi Aramco Desktop Standards.

LINE IDENTIFICATION (ENTRIES 1-6)

1 Indicate the complete official name of the line, and, if applicable, followed by an
abbreviation of the name in parenthesis, e.g., Fill-Suction Header No. 4 (FSH-4).
2 Show the year in which the line was originally constructed. In cases where Safety
Instruction Sheets are being prepared for existing pipelines for which only the
approximate date of construction is known, insert “(Approx.)” after the year. If the
approximate year the line was constructed is not known, record “unknown”.
3 Indicate the official name of the Terminal or Bulk Plant, e.g., Juaymah Tank Farm.
4 Indicate the name of the Department and Location of the facility, e.g., Terminal /
Ras Tanura.
5 Indicate the type of fluid handled, e.g., Arab Light Crude Oil, and record the year in
which the fluid handled by the line is as stated. Normally, this will be the same as
the year entered in key number 2.
6 Indicate the approximate total volume of the pipeline (rounded to the nearest
100 barrels). If the line volume is less than 100 barrels, give the volume to the
nearest ten barrels. Also, indicate the approximate total length of the pipeline
(rounded to the nearest 50 feet). If the line is less than 50 feet long, express the
length to the nearest ten feet.
PIPELINE DESIGN INFORMATION, OPERATING DATA & LIMITS (Entries 7-16)
7 Indicate the applicable ASME piping code; normally B31.4, but in some cases
B31.3.
8 If the pipeline is designed according to ASME B31.4, indicate the pipeline's internal
design pressure (IDP) as defined in paragraph 401.2.2 of that code. If the pipeline
is designed to ASME B31.3, indicate the pipeline's design pressure (DP) as
defined in paragraph 301.2 of that code. In addition to the applicable ASME code,
the design pressure must comply with SAES-L-310, “Design of Plant Piping”.
9 Indicate the design temperature, which must comply with SAES-L-310, “Design of
Plant Piping”.
10 Indicate whether the line is protected with a surge relief system.
11 If applicable, indicate the set pressure of the surge relief valves. If the line does
not have a surge relief system installed, record “N/A”.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

12 Indicate the maximum allowable surge pressure under the applicable piping code.
For piping designed according to ASME B31.4 this will normally be 1.1 times the
internal design pressure, and for piping designed according to ASME B31.3 this
will normally be 1.33 times the design pressure.
13 Indicate the general location of the surge relief valves, e.g., Inlet Metering Area.
If there is no surge relief system installed, record “N/A”.
14 Indicate the set pressure of any thermal relief valve(s) installed on the line. If there
are no thermal relief valves installed, indicate “N/A”.
15 Record the date and pressure of the hydrostatic pressure test performed on the
line immediately after construction. The test pressure shall be in accordance with
SAES-L-150, “Pressure Testing of Plant Piping and Pipelines”. If preparing a
Safety Instruction Sheet for an existing line for which this pressure and/or date are
not known, record “unknown”.
16 Record the date and pressure of the most recent hydrostatic pressure test.
For piping designed according to ASME B31.4 this should normally be 1.25 times the
internal design pressure, and for piping designed according to ASME B31.3 it should
normally be 1.5 times the design pressure. If the line has not been re-tested since
the initial hydrostatic pressure test, indicate the proper test pressure as determined
by the applicable piping code, and leave the date field blank.
Commentary Note:
The Safety Instruction Sheet (SIS) is to be updated by the responsible
Operations Engineering Unit after every hydrostatic pressure test.

PIPE DATA & MINIMUM THICKNESS REQUIREMENTS (Entries 17-38).

A separate column shall be completed for each unique segment of the line.
A single segment shall have same nominal pipe size, wall thickness, material
grade, design factor, flange rating, type of construction (buried or aboveground),
and coating specification.
17 Indicate the starting point for the piping segment covered by that particular column
on the SIS. Any appropriate point of reference can be used such as a pipe support
or MOV. If the section of piping is at a road crossing, record the applicable road
crossing number.
18 Indicate the end point for the segment of piping covered by that particular column
on the SIS.
19 Enter the nominal pipe size and pipe outside diameter of the segment of piping
covered by that particular column on the SIS.
20 Enter the nominal wall thickness of the segment of piping covered by that particular
column on the Safety Instruction Sheet. Fractions of an inch should be expressed
to 3 decimal places, e.g., “0.375 inch”.
Commentary Note:
Nominal wall thickness is the original wall thickness when the pipe was new,
and should not be confused with the actual wall thickness measured later
after corrosion may have occurred.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

21 Indicate the applicable Saudi Aramco Piping Specification as per SAES-L-105,

e.g., -1A1, 3CS9P, etc.
Commentary Note:
This specification should be the Saudi Aramco Piping Specification when the
line was originally constructed, even if this specification has since been
superseded.

22 Indicate the pipe material specification and grade, e.g., API 5L, Gr. B.
23 Indicate whether the pipe is welded or seamless.
24 For piping designed according to ASME B31.4, indicate the weld joint factor, E,
taken from Table 402.4.3 of that code (for most pipe grades this will be 1.00).
For piping designed according to ASME B31.3, indicate the longitudinal weld joint
quality factor, Ej, taken from Table 302.3.4 of that code.
25 For piping designed according to ASME B31.4, enter the appropriate design factor,
e.g., 0.50, 0.72, etc., in accordance with SAES-L-310 or SAES-L-410. If the piping
is designed according to ASME B31.3, record “N/A”.
Commentary Note:
If preparing a Safety Instruction Sheet for an existing line, record the design
factor that was used when the pipeline was designed.

26 If the piping is designed according to ASME B31.4, indicate the specified minimum
yield strength (SMYS) of the pipe. If the piping is designed according to ASME
B31.3, indicate the allowable stress (S) in accordance with Table A-1 of that code.
27 Indicate the class rating of the pipeline's flanges according to the applicable standard
(ASME B16.5, API 605, MSS SP-44, etc.), e.g., Class 150. If any unusual or non-
standard flanges are installed on the line, include a note in the Notes & Remarks
section providing details.
28 Enter a two letter abbreviation indicating the type of flange facing, e.g., RF for
raised face, RJ for ring joint, etc.
29 Enter the material specification of the main line flanges, e.g., ASTM A350 LF2,
ASTM 105N, etc. If there is more than one specification, write “see notes” in the
space provided, and then list the applicable specifications in a note in the Notes &
Remarks section.
30 State whether the segment of piping is buried or above ground.
31 Indicate the Saudi Aramco Coating Specification for the pipeline's external coating,
e.g., APCS-4. If the pipe is not externally coated, record “None”.
32 Indicate the Saudi Aramco Coating Specification for the pipeline's internal coating,
e.g., APCS-102. If the pipe is not internally coated, record “None”.
33 Indicate the pipe minimum wall thickness (Tmin), which shall not be less than the
greater of the following:
Minimum pressure thickness (Tp), which is the minimum wall thickness at which the
pipe can withstand an internal pressure equal to the internal design pressure
without exceeding the allowable hoop stress based on the pipe's SMYS, applicable

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

piping code, and design factor.

Minimum structural thickness (Ts) per Table I in SAES-L-310.
Commentary Note:
In some cases it may be necessary to specify a Tmin value thicker than both
Tp and Ts. This could be necessary due to longer than normal pipe support
spacing, presence of external loads, etc. In such cases, a detailed stress
analysis is to be performed to establish an appropriate Tmin.

34 If the piping is designed according to ASME B31.3, record the available corrosion
allowance (Tca), which equals the nominal wall thickness of pipe (key number 20)
minus Tmin (key number 33). If the pipe is designed according to ASME B31.4,
record “N/A”.
Commentary Note:
Corrosion allowance (Tca) is the remaining pipe wall thickness above the
required Tmin. 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 38.

35 Indicate the maximum pipe support spacing for which the Tmin value entered in key
number 33 is valid. This figure is the pipe support spacing at which the longitudinal
stress due to the combination of internal pressure and bending moment equals the
code allowable limit with the pipeline in the fully corroded condition, i.e., actual wall
thickness equals Tmin.
Commentary Note:
For piping designed according to ASME B31.4, the maximum pipe support
spacing (L) can be calculated using the following equation:

0.75S  PD 4t D 4  dc 4 
L
 2

D D 2  do 40.6  5.2d o
2

Where: L = Maximum Pipe Support Spacing, feet
S = Allowable Stress, psi (i.e., SMYS x E x D.F.)
P = Internal Design Pressure, psi
D = Pipe OD, inches
t = Tmin, inches
Tn = Pipe nominal wall thickness (before corrosion), inches
do = Pipe ID, before corrosion (Pipe OD minus 2Tn), inches
dc = Pipe ID after corrosion (Pipe OD minus 2t), inches
For piping designed according to ASME B31.3, the maximum pipe support
spacing (L) can be calculated using the following equation:

S  PD 4t D 4  d c 4 
L
 
D D 2  d o 40.6  5.2d o
2 2

Where: L = Maximum Pipe Support Spacing, feet
S = Allowable Stress, psi

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

P = Internal Design Pressure, psi

D = Pipe OD, inches
t = Tmin, inches
Tn = Pipe nominal wall thickness (before corrosion), inches
do = Pipe ID, before corrosion (Pipe OD minus 2Tn), inches
dc = Pipe ID after corrosion (Pipe OD minus 2t), inches
It is also acceptable to specify a maximum pipe support spacing longer than
the spacing calculated using this equation provided that a detailed stress
analysis is done to show the combined longitudinal stress levels being within
the limits of the applicable ASME piping code.

36 Enter the drawing number for the Valve Operating Diagram (VOD) for this line.
37 List applicable reference drawings such as isometric piping details (IPDs), Piping
and Instrument Diagrams (P&IDs), etc.
38 Include any required notes or remarks regarding entries on the subject Safety
Instruction Sheet. This will include explanations of any assumptions made for
entries when preparing a SIS for an existing line, and any other information that
may be useful for future reference.

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 Document Responsibility: Piping Standards Committee SAES-L-125
Issue Date: 10 July 2019
Next Planned Update: 31 August 2021 Safety Instruction Sheet for Piping and Pipelines

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