Engineering Procedure 11 October 2021

SAEP-29
General Instructions and Guidelines for Online Valve
Preventive Maintenance
Document Responsibility: Valves Standards Committee

Previous Revision: 18 November 2019 Next Revision: 11 October 2026

Contact: JARALLBM Page 1 of 13
© Saudi Arabian Oil Company, 2021

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

Contents
SUMMARY OF CHANGES ............................................................................................................................................ 3

1 SCOPE ................................................................................................................................................................. 4

2 CONFLICTS AND DEVIATIONS ............................................................................................................................. 4

3 REFERENCES........................................................................................................................................................ 4

4. TERMS, DEFINITIONS, ACRONYMS, ABBREVIATIONS ......................................................................................... 5

5. SAFETY PRECAUTIONS ........................................................................................................................................ 6

6. GENERAL INSTRUCTIONS .................................................................................................................................... 6

7. INSPECTION AND PREVENTIVE MAINTENANCE GENERAL GUIDELINES.............................................................. 7

DOCUMENT HISTORY................................................................................................................................................ 13

© Saudi Arabian Oil Company, 2021 Page 2 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

Summary of Changes
Paragraph Number Change
Previous Current Type
(Addition, Technical Change(s)
Revision Revision Modification,
(11 Nov 2019) (11 Oct 2021) Deletion, New)
Reworded the section for clarity.
Removed
“The objective of this document is to maintain the
1 1 Editorial performance of valves.”
Replaced the note with
“This document is not intended to cover corrective
maintenance including valve re-conditioning or major repair.”
3 3 Addition Included SAEP-302 and SABP-A-084
- 4 Addition added definitions
4 5 Editorial Renumbered each subsection
5 6 Editorial Renumbered each subsection
Replaced
“Critical valves shall be included in the T&I activities for visual
inspection, revalidation through shell and seat testing as a
minimum, and if deemed necessary complete overhauling.”
with
5.3 6.3 Modification
“Critical valves shall be identified by the proponent through a
formal assessment. Operations should maintain a list of all
identified critical valves.
Note: SABP-A-084 provides guidance on Asset Criticality
Assessment.”
6 7 Editorial Renumbered each subsection
Change the paragraph from
"Valve functionality shall be confirmed through
cycling/stroking. Notes: Stroking must be coordinated with
Operations. If full stroking is not possible, partial stroking must
be carried out. Pressure should be equalized across the valve
during stroking to avoid stroking difficulties, which might
cause wear or damage to parts or seals."
to
“Stroking must be coordinated with Operations.
6.4 7.4 Modification Valve functionality shall be confirmed through full stroke
testing.
If full stroke testing is not possible, partial stroke testing shall
be performed with 10% travel as a minimum; the stroke
percentage should be increased if process conditions allow.
For critical valves, full stroke testing shall be performed on a 5
year basis or at the Test & Inspection interval whichever is the
lesser.
Note: When feasible, seat sealing ability can be checked
for critical isolation valves as part of the PM program.”

© Saudi Arabian Oil Company, 2021 Page 3 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

1 Scope
This document provides general instructions and guidelines for online Preventive
Maintenance (PM) of metallic gate, globe, angle, check, needle, ball, plug, and
butterfly valves.
This document is not intended to cover corrective maintenance including valve
re-conditioning or major repair.
This document is intended to complement existing instructions and guidelines
only, and cannot cover all possible variations and combinations of specific valve
types and designs.
Manufacturer's instructions take precedence in the event of a conflict with the
instructions and guidelines in this document.
2 Conflicts and Deviations
Any conflict between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed in writing to
the EK&RD Manager.
Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.
3 References
All referenced specifications, standards, codes, drawings, and similar material
are considered part of this engineering procedure to the extent specified, applying
the latest version, unless otherwise stated.
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement.
SAEP-351 Bolted Flange Joints Assembly
Saudi Aramco Engineering Standards
SAES-B-058 Emergency Shutdown, Isolation, and Depressuring
SAES-H-001 Coating Selection and Application Requirements for
Industrial Plants and Equipment
SAES-H-002 Internal and External Coatings for Steel Pipelines and
Piping
SAES-J-601 Emergency Shutdown and Isolation Systems
SAES-L-108 Selection of Valves
Saudi Aramco Materials System Specifications

© Saudi Arabian Oil Company, 2021 Page 4 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

04-SAMSS-001 Gate Valves, Supplementary Requirements to IOGP S-611

04-SAMSS-035 General Requirements for Valves
Saudi Aramco General Instructions
GI-0002.100 Work Permit System
GI-0006.012 Isolation, Lockout and Use of Hold Tags
GI-0006.021 Abrasive Blast Operations
Saudi Aramco Best Practice
SABP-A-084 Asset Criticality Assessment (ACA) Guidelines
3.2 Industry Codes and Standards
American Petroleum Institute
API SPEC 6D Specification for Pipeline and Piping Valves
API RP 574 Inspection Practices for Piping System Components
API STD 598 Valve Inspection and Testing
American Society of Mechanical Engineers
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B31.3 Process Piping
Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.
MSS SP-45 Bypass and Drain Connections
4. Terms, Definitions, Acronyms, Abbreviations
4.1 Breakaway thrust / breakaway torque: Maximum thrust or torque required to
operate a valve at maximum pressure differential.
4.2 Partial Stroke Testing (PST): A test that initiates travel of the valve but limits
travel distance to an intermediate or partial stroke position.
Notes: Partial stroke testing can be used to confirm/verify the valve capability to
overcome breakaway thrust/torque. Partial stroke testing for example, cannot
confirm/verify the following:
• that an automated valve will fully seat
• that it is leak tight
• any travel beyond the PST position
• meet the response time for full travel
• reliably detect internal valve damage
4.3 ZV: See SAES-J-601.
4.4 Emergency Isolation Valve (EIV): See SAES-J-601.

© Saudi Arabian Oil Company, 2021 Page 5 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

5. Safety Precautions
Precautionary steps must be addressed clearly and adhered to prior to and during
maintenance and inspection of valves such as, but not limited to the following:
5.1 All required work permits shall be obtained in compliance with
GI-0002.100 prior to starting any work.
5.2 Maintenance personnel must be adequately trained.
5.3 Tools must be inspected to be fit for service, and have valid calibration where
applicable.
5.4 Work Area must be prepared; accessibility must be fully provided and inspected,
especially where scaffolding erection is required.
5.5 Atmospheric gas test must be performed prior to and during the job execution
(for potential toxic/hazardous services). In case venting or draining is required,
a procedure must be developed for isolation and safe venting & draining. Make
sure that all isolations, lockout and tags are performed in accordance with GI-
0006.012.
5.6 A fire watch person shall be available for auto-ignition services.
5.7 Never try to open any pressurized part (e.g., plug, drain, vent, etc.) of the valve
before verifying the valve is not subjected to line pressure.
Caution: Trapped pressure is expected. Precautions must be taken when opening valve
plugs, drains, vents or fittings.
5.8 For valves in-situ repairs, engineering procedure must be developed to include
depressurizing, isolation, draining and venting as per
SAES-B-058. The procedure shall also include disconnecting from any electrical
equipment and addressing all work location preparation.
5.9 Use adequate torque when trying to turn/operate a seized valve, bolt, or fitting.
Applying excess torque may cause the part to bend or break.
5.10 All safety related standards and requirements must be well addressed and
followed.
6. General Instructions
6.1 Preventive Maintenance (PM) of all valves shall be performed once annually.
Longer or shorter PM intervals can be assigned by the proponent based on:
• Valve Operational Criticality
• Risk of potential failure and associated consequence
• Service hazards and flowing medium severity
• Frequency of operation
• Maintenance and operational historical records

© Saudi Arabian Oil Company, 2021 Page 6 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

6.2 Intervals for PM of ZV and EIV shall be in accordance with SAES-J-601.

6.3 Critical valves shall be identified by the proponent through a formal assessment.
Operations should maintain a list of all identified critical valves.
Note: SABP-A-084 provides guidance on Asset Criticality Assessment.
6.4 A specific checklist of routine PM requirements shall be developed. Appendix A
shows a basic sample checklist.
6.5 Maintenance and Inspection data shall be logged and maintained.
6.6 During the PM, any abnormalities in the valve performance shall be further
evaluated/diagnosed and scheduled for maintenance and repair.
7. Inspection and Preventive Maintenance General Guidelines
7.1 Valve Body Visual
7.1.1 Clean and remove any dust, dirt or other deposits.
Notes: In case blasting is performed, all safety aspects shall be complied with as per
GI-0006.021. Valve identification data (tags and nameplates) shall be
adequately preserved during blasting and painting.
7.1.2 Inspect the valve general condition by checking the integrity of the paint,
and inspecting for signs of rust, external corrosion, oxidation, external
leakages, damage, or cracks. Check the required coatings and
applications as stated in SAES-H-001 and SAES-H-002.
7.1.3 Clean and check fittings, and ensure their compliance to SAES-L-108 and
04-SAMSS-035 for the types and materials of fittings.
7.1.4 Inspect the general conditions of all accessories, tubes and other
associated connections as recommended by API RP 574.
7.1.5 Examine the tightness of bolting such as body-to-bonnet, flange-line,
body-to-end closure when applicable to the valve design. Refer to SAEP-
351.
Note: Bolts may loosen due to frequent thermal cycles or vibration. Also, different
bolting materials have different torque requirements, reference the
manufacturer’s manuals, ASME B31.3, and ASME B16.5.
7.1.6 Portable hydrocarbon detection devices in accordance with Environmental
Protection Department (EPD) Leak Detection and Repair (LDAR) Protocol
may be used for leak detection.
7.2 Stem and Packing Condition
7.2.1 Clean the exposed section of the stem, check the stem/threads condition
and lubricate.
Note: For rising stem valve designs, stem protections (covers) should also be
checked. Lubrication type shall be compatible with the service conditions and
nonmetallic parts, refer to Manufacturer recommendations.

© Saudi Arabian Oil Company, 2021 Page 7 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

7.2.2 Check the packing system integrity, and inject lubricants/sealant if

necessary in accordance with the valve manufacturer’s recommendations.
Caution: For rising stem valve designs, online packing replacement shall be performed
only when full assurance of the backseat integrity can be verified and when
supported by an appropriate risk assessment study.
7.2.3 Replacement stem seals shall be in accordance with the applicable 04-
SAMSS and the valve manufacturer’s recommendations.
7.3 Valve Body/Seat Lubrication
7.3.1 Valve seats equipped with injection fittings shall be lubricated accordingly.
Note: The type of lubricants shall be compatible with the service conditions. Refer to
Manufacturer recommendations.
7.3.2 Cleaning and flushing chemical injection shall be used whenever needed
such as when back pressure buildup is observed during the lubrication
activities or for contaminant removal.
Caution: Always operate the lubrication equipment in accordance with the
manufacturer’s instructions. Do not exceed the maximum injection pressure.
7.4 Stroking
Stroking must be coordinated with Operations.
Valve functionality shall be confirmed through full stroke testing.
If full stroke testing is not possible, partial stroke testing shall be performed with
10% travel as a minimum; the stroke percentage should be increased if process
conditions allow.
For critical valves, full stroke testing shall be performed on a 5 year basis or at
the Test & Inspection interval whichever is the lesser.
Note: When feasible, seat sealing ability can be checked for critical isolation valves
as part of the PM program.
7.5 Draining of Body Cavity
Check the compliance of drain and vent connections with 04-SAMSS-035 and
MSS SP-45.
Sealing integrity of a double block and bleed valve (refer to API SPEC 6D, Section
3.1.10) may be checked by draining the cavity and checking whether the leakage
is within the acceptable limit (refer to API STD 598, and/or API SPEC 6D).
The draining must be handled with extreme caution as high pressure material
may be released. Also; hazardous (toxic and/or otherwise poisonous, flammable
or explosive) materials might be drained, and thus draining must be contained
through a safe system in an environmentally responsible manner.
7.6 Valve Gearbox

© Saudi Arabian Oil Company, 2021 Page 8 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

7.6.1 Check for any signs of leakage from the gearbox cover; replace any
damaged seals and O-rings to prevent water from entering the gearbox
causing corrosion problems.
7.6.2 Top off the gearbox with lubricants as needed.
Notes: The selection of the gearbox lubricant type shall be in accordance with the
specification of the original equipment manufacturer. Gearbox shall not be
overfilled to avoid damaging (e.g., blowout) the weather/ingress protection
seal.
7.6.3 If sound or vibration is noticed in the gearbox during the valve stroking,
remove the gearbox cover to inspect the condition of the gear mechanism.
Remove any dirt, sludge, and corrosion. Replace damaged parts, if any,
and cover seals. Finally, top off the gearbox with lubricant.
7.7 Actuator
7.7.1 Visual Inspection
a) Remove dust and dirt build up from the surfaces.
Note: Dirt build up can inhibit cooling causing the temperature of the actuator to rise
above the maximum allowable level.
b) Inspect the actuator body for any cracks or paint work damage.
Touch up as required to ensure continued corrosion protection.
c) Check the condition of all actuator to valve mounting bolts.
Tighten/replace as necessary.
d) Check actuator for lubricant/fluid leaks.
e) Inspect gear drive condition check for moisture ingress or
contaminants, and replace cover gaskets in accordance with
original equipment manufacturer recommendations. Then, report
finding.
Note: When refitting or replacing bolts, enclosure covers, and fasteners in corrosive
environments, apply applicable lubricant to threads and hinges to prevent
seizure or damage from corrosion.
7.7.2 Removal of covers may impact the ingress protection/certification of the
actuator, refer to the original equipment manufacturer recommendations.
7.7.3 Always refer to the original equipment manufacturer instructions,
recommendations, and drawings, when replacing bolting (i.e., to ensure
the correct bolting is loosened).
7.7.4 Additional Requirements for Motor Operated Valve
a) Check condition for all cables, conduits, fittings, earth connections
and fasteners.
b) Inspect and clean all relays, push button assembly, and contactors.
Check fuses for correct rating. Refer to Manufacturer Data.

© Saudi Arabian Oil Company, 2021 Page 9 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

Note: Check electrical compartment enclosure ‘O’-ring for nicks, cuts and any
damage whenever an access cover is removed.
c) Check Torque switch setting and operation.
d) Check limit switch settings & adjust if necessary. If the actuator is
explosion proof, the integrity of the flame path shall be checked
(Refer to Manufacturer data).
e) Check the motor starter contacts/interlocks.
f) Check the signal indicator for correct indication during the valve
cycling.
g) For the digital MOV's, check all cards from sign of damage or
discoloration, check the display screen is readable.
h) Check the Actuator 9V/Lithium battery and record the reading,
replace if needed.
Caution: All maintenance activities of the actuator must be carried out only after having
isolated the actuator from the electrical supply to prevent hazard.
7.7.5 Additional Requirements for Gas Operated Valve
a) Check actuator mechanism for visible hydraulic leaks & audible gas
leak during static and operation modes.
b) Check and clean inside cabinets, flow valves, equipment and
piping. Inspect and rectify any gas or oil leaks on valves, hand
pumps, oil reservoirs and tubing connections. Replace any
damaged tubing and check security of all piping clamps.
c) Check the regulators and pressure switches functionality.
Caution: Extreme caution needs to be taken while working with any pressurized system.
Always isolate, vent & depressurize prior to disconnection of any part.
d) Check and record gas/nitrogen supply pressure. Check gas supply
filters. Drain, strip and clean/replace if necessary.
e) Check Hydraulic System: Lubricate hand pump and changeover
valve linkages, pins, and valve spindle. Check the top and bottom
seal of the hydraulic oil cylinders. Check oil levels in accumulator
bottles and tanks. Clean filters, check pump couplings and top up
oil level.
f) Check pressure gauges conditions and functionality.
g) Ensure the cabinet door seals are undamaged to prevent
dust/sands ingress.
h) Check the Solenoid functionality.

© Saudi Arabian Oil Company, 2021 Page 10 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

i) Check the limit switch and the external indicator and adjust if
necessary. Ensure limit switch and position indicator signals are
properly set & displayed.
7.7.6 Functional Test
The functional test procedure of each individual valve needs to be
prepared by the operational department based on the valve specification,
proponent experience, and vendor recommendation. The following steps
should be included:
a) Check manual operation of actuator engagement and
disengagement for smooth operation. Check if mechanical valve
position indicators and the actuator stops are correctly set.
b) Check power operation of the valve both locally and remotely,
preferably fully stroking valve or to maximum possible stroke
depending upon system flexibility.
c) Check the stroking speed if required.
Caution: Stop the motor immediately if any sign of incorrect operation. It is vital that
toque/limit switches are set correctly; incorrect setting may cause damage to
the valve internals. Readjust the setting if necessary, per manufacturer’s
guidelines. Do not operate the actuator continually to avoid overheating.

© Saudi Arabian Oil Company, 2021 Page 11 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

Appendix A: Sample Checklist for Preventive Maintenance

VALVE NUMBER:____________
********************************************************
* *
* ENSURE SAFETY PROCEDURES ARE FOLLOWED AT ALL TIMES. *
* *
********************************************************
SAFETY: Does this job require electrical disconnection.
(if so, make sure that the breakout is done for the same valve).
EQUIPMENT: Make sure that all tools are checked and fit for service.

1. Inform operations of PM and obtain cold/hot work permit.

And the work area is accessible and safe for work. _____
2. Compare the information above of the work order against
the valve tag number (equipment name plate). _____
3. Clean and check the body appearance and ensure no rust, external
corrosion, oxidation, leakages, and cracks. _____
4. Examine the tightness of bolting such as body-bonnet,
flange-line. _____
5. Check stem seal and gland packing for oil leaks. _____
6. Clean/grease the valve stem. _____
7. Stroke the valve from fully open to fully close
and return back to open (or vice versa). _____
8. Ensure that the valve operates smoothly
and there are no abnormal sounds/motion/vibrations. _____
9. Clean area of any materials, tools, etc. _____
10. Inform operations that the PM has been completed
and close the work permit. _____
If any additional work was done or required, please give
details below or on the back of this sheet.

Comments:__________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________

© Saudi Arabian Oil Company, 2021 Page 12 of 13

Saudi Aramco: Company General Use

 Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 11 October 2021 General Instructions and Guidelines
Next Revision: 11 October 2026 for Online Valve Preventive Maintenance

Document History

11 October 2021 Major revision.

18 November 2019 Major revision to change next revision cycle

27 November 2014 Major revision as relevant SA General Instructions were clearly

addressed in a safety precaution section to ensure safety during
performing Valve PM.

© Saudi Arabian Oil Company, 2021 Page 13 of 13

Saudi Aramco: Company General Use