SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL

EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER

EQPT CODE

SYSTEM ID.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME

ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO USE ONLY

WORK PERMIT REQUIRED?

ITEM No. A

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Test Preparation - General Requirements ... USE SATR-A-2001, 2002, 2003, 2004, 2005 & SATR-A-2006 as req'd. Pressure Test Package meets Attachment 1 minimum content requirements. (Reviewed/approved/signed). See SAIC-A-2003. Note 1: Package contents were reviewed carefully. Note 2: Document deficiencies are noted in package for action. Pre-Test Punchlisting is complete (per procedure). All "A" items are cleared & accepted* (*Test Pkg Flow Chart is also signed off) Note: "A" items are Pre-test Punchlist items that must be complete prior to safe pressure testing of systems per approved procedure. Permanent Flange set installations are documented/accepted. Note: Flanges that will not be disturbed after the pressure test are marked/identified and tightened & QC records are per approved procedure & available. See also SAIC-L-2014 & SATR-L-2001. System Flushing and internal Cleanliness is complete. Test Package Flow chart is signed-off. New systems and equipment in Plants were cleaned per approved procedures per SAES-L-350. Component Safeguards (temporary removals/test exclusions) exist for new systems to prevent damage caused by filling, venting, draining, flushing or testing. These are itemized on Reinstatement and Pre-Test Checklists and are found in Test Pkgs/Procedures. See Safeguards listed in Attachment 2. Temporary supports are installed if they were determined to be required per SAES-L-150. Expansion joints and spring hangers or spring supports are provided with temporary restraints where needed to prevent excessive travel or deformation under the test loads. (Field Verify) All joints including welded joints are accesible and left exposed for visual leak detection during the strength test. Note: This excludes joints subject to 24-hr recorded test Work permit is obtained for pressure testing and associated work within restricted areas, as per G.I. 2.100, Work Permit System. Equipment & appurtenances (Attachments, auxilliary equipment, etc) that are not adequate for test pressures are isolated from test. If an isolation valve is used for a test boundary, in lieu of test blind, ensure that no overpressurization damage can occur in any equipment beyond the isolation valve (due to valve leak-by) by: a) Reduction of test pressure (rule = 1.1 times valve press rating) b) Open isolation valve drain (or nearest adjacent low-point drain) c) Relief valves placed on both sides of isolation valve. (Para. 7.3) d) Personnel are posted during testing to identify any valve leak-by. e) Personnel control/stop pressurization (Valve leak-by evidence). See Remarks Section (Safety Note 1) MSDS or Chemical Hazard Bulletins is available/reviewed for all chemicals handled (corrosion inhibitor, bactericide, chlorine, oxygen scavenger, etc). Written procedure to safely handle chemicals during testing & to ensure proper disposal after testing is approved. SAEP-1160, Section 8

A1

A2

SAEP-1160, Section 8

A3

SAEP-1160, Section 8

A4

SAES-A-004, Para. 7.1.2

A5

SAES-A-004, Section 7

A6

SAES-A-004, Para. 7.5.2 SAES-L-150, Para. 6.4 SAES-L-150, Para. 7.3 G.I.-2.102, Para. 5.6 G.I.-2.102, Para. 5.7

A7

A8

A9 A10

A11

G.I.-2.102, Para. 5.7, Para 7.3

A12

G.I.-2.102, Para. 5.9

Page 1 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. A13

ACCEPTANCE CRITERIA Personal protective equipment (PPE) is available and utilized as shown on these sheets and bulletins for chemical handling. Access/Egress for Test areas is marked & warning signs posted to alert approaching personnel of pressure testing activities. Where a road parallels within 30 m (100 ft.) of an aboveground pipeline being tested, traffic shall be diverted or stopped during the test. If this is not practical, the area Loss Prevention offices should be contacted to confirm that the test can be conducted safely. If non-Saudi Aramco facilities will be exposed in a pressure test of SA facilities, the proponent organization of the test shall so inform the Saudi Aramco Affairs representative prior to the test. Copy of the approved pressure testing procedure & the GI-2.102 are available at site. Test Personnel are safety trained/experienced. Verification of Actual Test Set-up & SIS Sheet Data:

REFERENCE G.I.-2.102, Para. 5.9 G.I.-2.102, Para. 5.11

PASS

FAIL

N/A

RE-INSP DATE

A14

A15

G.I.-2.102, Para. 5.11

A16

G.I.-2.102, Para. 5.12

A17

SAES-A-004, Para. 5.1

B1

Test Set-up* matches actual test arrangement (drawings). Note 1: *Pressure Test Diagram with an appropriate Legend for symbols, Test Manifold Arrangement (& pressure hoses/piping) show all high points (vents), low points (drains), gage locations & provide documentation that attests to the actual test as performed. In event of testing accident, Loss Prevention Dept must be able to use diagrams & sketches to recreate actual test set-up/conditions. Note 2: Testing of multiple lines (test pkgs) on projects can be done by proper hose arrangement, filling & venting to save time. Sketch & show the actual hose arrangement(s) in test packages. Correct any errors in arrangement found, initial & date sketches.

SAEP-1160, Section 8 Bullet Item 2

B2

SIS Sheet Data (pressure, limiting factor, medium & temperature) is checked* for accuracy against the test application and is correct. *Note: Human error (test package calcs) is common. Inspectors responsible for testing are able to spot gross errors & prevent unsafe testing & overpressurization of systems & components. Test Manifold & Appurtanances (Piping, Fittings, Hoses) Pressure testing manifolds were separately pressure tested to at least 1.2 times system test pressure. (Manifold Test Report/Cert) Pressure rating or design of test manifold components* (isolation valves, pipe nipples, fittings) exceed system test pressure by 20%. See Safety Note 1 in Remarks for isolation valves Manifold Arrangement Drawings attest to the following: A) Fabrication was per code construction with component details listed such as Class, size, schedule, type isolation valve, etc. B) Maximum Safe Test Pressure Rating based on limiting factor. C) Each test manifold is identified with a unique number (certificate) D) Shows actual arrangement including hose configuration used Note 1: Manifold permanent marking (unique ID #, pressure rating) is legible, traceable & certified (Engineering support docs).

SAEP-1160, Section 8 Bullet Item 2

C1

SAES-A-004 Para 5.5.4

C2

G.I.-2.102, Para. 5.5

C3

G.I.-2.102, Para. 5.5

Page 2 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Manifolds proposed for use on projects without detailed code construction certification (Engineering calcs & Inspection) must be evaluated for fitness and safety. Provide necessary details and support test manifolds with any necessary calculations (SIS sheet) and the appropriate visual Inspection and any necessary NDE. Note: Unknown piping schedules can be determined by using a UT Thickness meter. Weld quality is verified by VT or RT. A blow down valve of adequate pressure rating is installed to depressurize the system safely (easily accessible to operator). Test piping, fittings and hoses are designed or have adequate pressure ratings that match or exceed system class/ test pressure. Paddles or spectacle blinds & other fabricated test items used to isolate test sections are at least the same code class rating of systems under test or are supported by appropriate code calcs. See Remarks, Critical Safety Note 2 Test Relief Valve(s) Relief valve is located in the system under test and near the test pump with Isolation valves on the inlet and outlet of the relief valve sealed open during the test. (SAEP-1160, Bullet Item # 3) Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available) are set to relieve at 5%* above the hydrotest pressure. *Note: Test pressures less than 85% of SMYS can have relief valves set at 10% above test pressure. Verify SIS sheets calcs. Relief valve(s) are tested, dated, and tagged (as valid) for a period of one week for project pressure tests. Stickers are legible & valid. Pressure Gages and Recorders

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

C4

G.I.-2.102, Para. 5.5

C5

G.I.-2.102, Para. 5.5 G.I.-2.102, Section 4

C6

C7

SAES-A-004 Para. 7.3

D1

G.I.-2.102, Para. 5.5

D2

SAES-A-004 Para 5.5.1

D3 E

SAES-A-004 Para 5.5.1

E1

A minimum of two pressure gages are required for test systems, with accuracy within 5% of one another. Note 1: When large systems are tested, Inspection personnel will determine the need for additional gages. Note 2: Elevation changes (hydrostatic head considerations) & hot weather create pressure testing problems with frequent popping of relief valves. For this reason, gage accuracy within 2% is best. Note 3: Careful handling of delicate instruments like test gages is practiced by test crews. No gage damage or mishandling is found.

SAES-A-004 Para 7.1.5

E2

Pressure gages and pressure recorders are calibrated within (1) month prior to test. Stickers applied indicate latest calibration date. Test gauge is located at bottom of any equipment/system under test to enable reading test pressures inclusive of hydrostatic head. Note: Locate test manifold (with gage) at low points in systems under test. One foot of water (30 cm) @ ambient temperature = pressure increase of .433 psi. (1-meter = 1.42, 10-meter = 14 psi). All gages have a range such that the test pressure is within 30% to 80% of the full range.

SAES-A-004 Para 7.1.5

E3

G.I.-2.102, Sec.4 & SAES-A-004, Para 5.3

E4

SAES-A-004 Para 7.1.5

Page 3 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. F

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Temperature Gages and Recorders (When Required, ie: 24-hr Recorded Tests) Bubble Leak Test (associated with Pneumatic strength/service test) surface metal temperatures shall be recorded and compatible with test methods (including test solution used to detect leaks). Note: ASME V, Art 10, Man. App. 1, Table 1-1021 requires surface metal temp measurements during testing (detailed in procedure). Record maximum (direct sun) & minimum test temperatures. Thermocouples are installed to obtain accurate pipe metal temperature measurements and to determine the acceptance of the pressure test where pressure variations due to test water temperature changes occur, such as in cross-country pipelines.

F1

SAES-A-004 Para 5.6.1

F2

SAES-L-150, Para. 11.3

REMARKS: Critical Safety Note 1: Surveys of test manifolds used on projects have resulted in many findings of inadequate ratings for isolation valves. Test manifolds for testing specific pressure rating Classes require isolation valves of the next higher class. Example: Manifolds for testing Class 300 # systems require Class 600 # isolation valves as a general rule. For Pressure tests against closed seats follow the 110% rule for safe test pressure calculation. See ASME B16.34, Para 7.2 as applicable. Also, this same requirement must be carefully considered when determining test pressures where an isolation valve serves as a test boundary limit and the valve seat will be pressurized. Ensure system test pressures are reduced to 110% as applicable and show the valve seat as the test "limiting factor". Safety Note 2: Fabricated test implements of proper code construction receive inspection and properly identification/marking for pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never allow uninspected non-code test implement use or those that are unfit for testing (deteriorated, damaged, heavily corroded). Unsafe/unfit test implements found are reported/removed ASAP from Company Projects. REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely, (22 July, 2001) 3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003) 4. Pro Forma Contract Schedule Q (Nov 2003) 5. SAEP-1160 (First Edition June 7, 2006)

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

QC Inspector
Performed Inspection Name, Initials and Date: Work / Rework May Proceed

PID Representative
T&I Witnessed Name, Initials and Date: QC Record Reviewed Work Verified

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

Name, Organization, Initials and Date: T&I Witnessed QC Record Reviewed Work Verified

Y = YES

N = NO F = FAILED

Page 4 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011

1-Dec-06

MECH-

Attachment 1 - SAEP-1160 Test Pkg Minimum Requirements

Page 5 of 11

Attachment 2 - Component Safeguard Summary

Note: This Summary Checklist has been developed with concurrence of CSD

1. INSTALL THESE COMPONENTS IN LINE ONLY AFTER THOROUGH FLUSHING:

Soft seated valves & control valves (SAES-A-004, Para. 7.1.3)

2. INSTALL THESE COMPONENTS IN LINE AFTER FLUSHING & TEST COMPLETION (ON REINSTATEMENT):
Components in new piping systems which interfere with filling, venting, draining or flushing shall not be installed until after line flushing and pressure testing are completed. This includes Procedures/Test Package Instruction or details about specific component care as listed below (SAES-A-004, Para 7.1.4): a) Orifice plates -- Flow nozzles -- Sight glasses (incl. vessel trim) -- Venturies -- Meters (positive displacement, turbine) b) In-line equipment (as determined by Proponent) includes valve care (corrosion, cleaning, lay-up considerations). A list shall be obtained by Contractor from COMPANY relative to Component Safeguards. Contractor shall request specific instruction for specific component safeguards from Company (Proponent, SAPMT, SA Inspection)

3. INSTALL THESE COMPONENTS (EXCLUDED FROM PRESSURE TEST) ON FINAL REINSTATEMENT:

Note: The following list defines the equipment that shall be excluded from the in-situ pressure testing of the tested system. Also, other unlisted sensitive equipment or as designated by SA Inspector can be added (Para 7.2): a) Rotating machinery, such as pumps, turbines and compressors; b) Strainers and filter elements c) Pressure relieving devices, such as rupture disks and pressure relief valves; d) Locally mounted indicating pressure gauges, where the test pressure will exceed their scale range; e) Equipment that cannot be drained (This includes valve cavities. See Valve Care below). f) Instrument Devices. g) Other unlisted sensitive equipment (propose exclusion in test package) h) Equipment designated by Saudi Aramco Inspector (Approves procedures that list specific equipment in scope)

CSD VALVE SAFEGUARDS & CARE (TYPICAL FOR AMBIENT LAY-UP) Valve Field Hydrotest Practice (separate from line/system testing) assures adequate preservation as listed below. Valves or
other equipment that are field tested prior to installation in a pipeline, plant, or other facility are likely to experience corrosion damage if this is not performed with adequate diligence and precautions. a) The following applies to valve trims Type 1, 4, 6, 7, 8, and 8A and all solid Type 400 SS (13 CR) valves. b) Plan prior field testing of valves to minimize the length of time between test and installation in the system. c) All critical isolation valves that are tested shall be tested with water containing less than 50 ppm chlorides. The water shall contain 0.5% by weight (5 grams per liter) Cortec VpCI 609. (Note:Chemical cost would be about $0.30 per liter. VpCI 609 is biodegradable so there are no problems with its use. (See Environmental Protection Dept.) d) After hydrotesting, gate valves will have their gates raised to allow full draining of water. Allow adequate drainage time. All traces of visible water shall be removed from the valve body and seat area. Blow dry with clean compressed air. e) Apply manufacturer approved lubricant plus 10% Cortec VpCI-329 (SAP 1000173887) added to all interior critical surfaces such as seal areas. Ball valves shall be full operated to distribute inhibited lubricant between ball and body.

Constructed Piping Hydrotest Practice (Valve Safeguards)

a) Hydrotest plans for constructed field equipment shall be designed to minimize exposure of valves to hydrotest water. Unless it is absolutely unavoidable, critical isolation valves (Field Hydrotested) shall be installed after completion of hydro. b) Piping systems shall be thoroughly flushed before hydrotesting to remove wind-blown sand, construction debris, and any other foreign matter. Flushing water shall be the same quality as the hydrotest water. Hydrotest shall be performed immediately after flushing or the line shall be properly layed-up per SAES-A-007 Procedures (30-day rule). c) If any 400 series (13 CR) trimmed valves are pre-installed & hydrotested in the line, utilize test gaskets and thoroughly drain test water immediately after the test. Where complete draining is impossible (no valve body drain plug), valves shall be removed immediately after test, dried with clean compressed air and re-lubricated before "ambient" lay-up. Ensure that there is no debris in the seat area. d) Any 400 series (13 CR) trimmed valves that are pre-installed and hydrotested in the line, and that have body or seat drains and are in place when field pipework is hydrotested shall be treated with Cortec VpCI 609 by blowing into all possible valve injection locations immediately after completion of the hydrotest and draining of all water. e) Any 400 series (13Cr) trimmed valves that are pre-installed welded-in-place shall be liberally coated with inhibited lubricant before final welding into the line. f) Safeguards for 300 series (316 SS, etc) trimmed valves require similar care to assure complete cavity draining. Corrosion inhibitors used shall be approved by CSD.

Page 6 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. A13 A14

ACCEPTANCE CRITERIA Personal protective equipment (PPE) is available and utilized as shown on these sheets and bulletins for chemical handling. Access/Egress for Test areas is marked & warning signs posted to alert approaching personnel of pressure testing activities. Where a road parallels within 30 m (100 ft.) of an aboveground pipeline being tested, traffic shall be diverted or stopped during the test. If this is not practical, the area Loss Prevention offices should be contacted to confirm that the test can be conducted safely. If non-Saudi Aramco facilities will be exposed in a pressure test of SA facilities, the proponent organization of the test shall so inform the Saudi Aramco Affairs representative prior to the test. Copy of the approved pressure testing procedure & the GI-2.102 are available at site. Test Personnel are safety trained/experienced. Verification of Actual Test Set-up & SIS Sheet Data: Test Set-up* matches actual test arrangement (drawings). Note 1: *Pressure Test Diagram with an appropriate Legend for symbols, Test Manifold Arrangement (& pressure hoses/piping) show all high points (vents), low points (drains), gage locations & provide documentation that attests to the actual test as performed. In event of testing accident, Loss Prevention Dept must be able to use diagrams & sketches to recreate actual test set-up/conditions. Note 2: Testing of multiple lines (test pkgs) on projects can be done by proper hose arrangement, filling & venting to save time. Sketch & show the actual hose arrangement(s) in test packages. Correct any errors in arrangement found, initial & date sketches. SIS Sheet Data (pressure, limiting factor, medium & temperature) is checked* for accuracy against the test application and is correct. *Note: Human error (test package calcs) is common. Inspectors responsible for testing are able to spot gross errors & prevent unsafe testing & overpressurization of systems & components. Test Manifold & Appurtanances (Piping, Fittings, Hoses) Pressure testing manifolds were separately pressure tested to at least 1.2 times system test pressure. (Manifold Test Report/Cert) Pressure rating or design of test manifold components* (isolation valves, pipe nipples, fittings) exceed system test pressure by 20%. See Safety Note 1 in Remarks for isolation valves Manifold Arrangement Drawings attest to the following: A) Fabrication was per code construction with component details listed such as Class, size, schedule, type isolation valve, etc. B) Maximum Safe Test Pressure Rating based on limiting factor. C) Each test manifold is identified with a unique number (certificate) D) Shows actual arrangement including hose configuration used Note 1: Manifold permanent marking (unique ID #, pressure rating) is legible, traceable & certified (Engineering support docs).

REFERENCE G.I.-2.102, Para. 5.9 G.I.-2.102, Para. 5.11 G.I.-2.102, Para. 5.11

PASS

FAIL

N/A

RE-INSP DATE

A15

A16

G.I.-2.102, Para. 5.12 SAES-A-004, Para. 5.1

A17 B

B1

SAEP-1160, Section 8 Bullet Item 2

B2

SAEP-1160, Section 8 Bullet Item 2

C C1

SAES-A-004 Para 5.5.4 G.I.-2.102, Para. 5.5

C2

C3

G.I.-2.102, Para. 5.5

Page 7 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Manifolds proposed for use on projects without detailed code construction certification (Engineering calcs & Inspection) must be evaluated for fitness and safety. Provide necessary details and support test manifolds with any necessary calculations (SIS sheet) and the appropriate visual Inspection and any necessary NDE. Note: Unknown piping schedules can be determined by using a UT Thickness meter. Weld quality is verified by VT or RT. A blow down valve of adequate pressure rating is installed to depressurize the system safely (easily accessible to operator). Test piping, fittings and hoses are designed or have adequate pressure ratings that match or exceed system class/ test pressure. Paddles or spectacle blinds & other fabricated test items used to isolate test sections are at least the same code class rating of systems under test or are supported by appropriate code calcs. See Remarks, Critical Safety Note 2 Test Relief Valve(s) Relief valve is located in the system under test and near the test pump with Isolation valves on the inlet and outlet of the relief valve sealed open during the test. (SAEP-1160, Bullet Item # 3) Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available) are set to relieve at 5%* above the hydrotest pressure. *Note: Test pressures less than 85% of SMYS can have relief valves set at 10% above test pressure. Verify SIS sheets calcs. Relief valve(s) are tested, dated, and tagged (as valid) for a period of one week for project pressure tests. Stickers are legible & valid. Pressure Gages and Recorders A minimum of two pressure gages are required for test systems, with accuracy within 5% of one another. Note 1: When large systems are tested, Inspection personnel will determine the need for additional gages. Note 2: Elevation changes (hydrostatic head considerations) & hot weather create pressure testing problems with frequent popping of relief valves. For this reason, gage accuracy within 2% is best. Note 3: Careful handling of delicate instruments like test gages is practiced by test crews. No gage damage or mishandling is found. Pressure gages and pressure recorders are calibrated within (1) month prior to test. Stickers applied indicate latest calibration date. Test gauge is located at bottom of any equipment/system under test to enable reading test pressures inclusive of hydrostatic head. Note: Locate test manifold (with gage) at low points in systems under test. One foot of water (30 cm) @ ambient temperature = pressure increase of .433 psi. (1-meter = 1.42, 10-meter = 14 psi). All gages have a range such that the test pressure is within 30% to 80% of the full range.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

C4

G.I.-2.102, Para. 5.5

C5 C6

G.I.-2.102, Para. 5.5 G.I.-2.102, Section 4 SAES-A-004 Para. 7.3

C7

D1

G.I.-2.102, Para. 5.5

D2

SAES-A-004 Para 5.5.1 SAES-A-004 Para 5.5.1

D3 E

E1

SAES-A-004 Para 7.1.5

E2

SAES-A-004 Para 7.1.5 G.I.-2.102, Sec.4 & SAES-A-004, Para 5.3 SAES-A-004 Para 7.1.5

E3

E4

Temperature Gages and Recorders (When Required, ie: 24-hr Recorded Tests)

Page 8 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Bubble Leak Test (associated with Pneumatic strength/service test) surface metal temperatures shall be recorded and compatible with test methods (including test solution used to detect leaks). Note: ASME V, Art 10, Man. App. 1, Table 1-1021 requires surface metal temp measurements during testing (detailed in procedure). Record maximum (direct sun) & minimum test temperatures. Thermocouples are installed to obtain accurate pipe metal temperature measurements and to determine the acceptance of the pressure test where pressure variations due to test water temperature changes occur, such as in cross-country pipelines.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

F1

SAES-A-004 Para 5.6.1

F2

SAES-L-150, Para. 11.3

REMARKS: Critical Safety Note 1: Surveys of test manifolds used on projects have resulted in many findings of inadequate ratings for isolation valves. Test manifolds for testing specific pressure rating Classes require isolation valves of the next higher class. Example: Manifolds for testing Class 300 # systems require Class 600 # isolation valves as a general rule. For Pressure tests against closed seats follow the 110% rule for safe test pressure calculation. See ASME B16.34, Para 7.2 as applicable. Also, this same requirement must be carefully considered when determining test pressures where an isolation valve serves as a test boundary limit and the valve seat will be pressurized. Ensure system test pressures are reduced to 110% as applicable and show the valve seat as the test "limiting factor". Safety Note 2: Fabricated test implements of proper code construction receive inspection and properly identification/marking for pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never allow uninspected non-code test implement use or those that are unfit for testing (deteriorated, damaged, heavily corroded). Unsafe/unfit test implements found are reported/removed ASAP from Company Projects. REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely, (22 July, 2001) 3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003) 4. Pro Forma Contract Schedule Q (Nov 2003) 5. SAEP-1160 (First Edition June 7, 2006)

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

QC Inspector
Performed Inspection Name, Initials and Date: Work / Rework May Proceed

PID Representative
T&I Witnessed Name, Initials and Date: QC Record Reviewed Work Verified

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

Name, Organization, Initials and Date: T&I Witnessed QC Record Reviewed Work Verified

Y = YES

N = NO F = FAILED

Page 9 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011

1-Dec-06

MECH-

Attachment 1 - SAEP-1160 Test Pkg Minimum Requirements

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2011

1-Dec-06

MECH-

Attachment 2 - Component Safeguard Summary

Note: This Summary Checklist has been developed with concurrence of CSD

1. INSTALL THESE COMPONENTS IN LINE ONLY AFTER THOROUGH FLUSHING:

Soft seated valves & control valves (SAES-A-004, Para. 7.1.3)

2. INSTALL THESE COMPONENTS IN LINE AFTER FLUSHING & TEST COMPLETION (ON REINSTATEMENT):
Components in new piping systems which interfere with filling, venting, draining or flushing shall not be installed until after line flushing and pressure testing are completed. This includes Procedures/Test Package Instruction or details about specific component care as listed below (SAES-A-004, Para 7.1.4): a) Orifice plates -- Flow nozzles -- Sight glasses (incl. vessel trim) -- Venturies -- Meters (positive displacement, turbine) b) In-line equipment (as determined by Proponent) includes valve care (corrosion, cleaning, lay-up considerations). A list shall be obtained by Contractor from COMPANY relative to Component Safeguards. Contractor shall request specific instruction for specific component safeguards from Company (Proponent, SAPMT, SA Inspection)

3. INSTALL THESE COMPONENTS (EXCLUDED FROM PRESSURE TEST) ON FINAL REINSTATEMENT:

Note: The following list defines the equipment that shall be excluded from the in-situ pressure testing of the tested system. Also, other unlisted sensitive equipment or as designated by SA Inspector can be added (Para 7.2): a) Rotating machinery, such as pumps, turbines and compressors; b) Strainers and filter elements c) Pressure relieving devices, such as rupture disks and pressure relief valves; d) Locally mounted indicating pressure gauges, where the test pressure will exceed their scale range; e) Equipment that cannot be drained (This includes valve cavities. See Valve Care below). f) Instrument Devices. g) Other unlisted sensitive equipment (propose exclusion in test package) h) Equipment designated by Saudi Aramco Inspector (Approves procedures that list specific equipment in scope)

CSD VALVE SAFEGUARDS & CARE (TYPICAL FOR AMBIENT LAY-UP) Valve Field Hydrotest Practice (separate from line/system testing) assures adequate preservation as listed below. Valves or
other equipment that are field tested prior to installation in a pipeline, plant, or other facility are likely to experience corrosion damage if this is not performed with adequate diligence and precautions. a) The following applies to valve trims Type 1, 4, 6, 7, 8, and 8A and all solid Type 400 SS (13 CR) valves. b) Plan prior field testing of valves to minimize the length of time between test and installation in the system. c) All critical isolation valves that are tested shall be tested with water containing less than 50 ppm chlorides. The water shall contain 0.5% by weight (5 grams per liter) Cortec VpCI 609. (Note:Chemical cost would be about $0.30 per liter. VpCI 609 is biodegradable so there are no problems with its use. (See Environmental Protection Dept.) d) After hydrotesting, gate valves will have their gates raised to allow full draining of water. Allow adequate drainage time. All traces of visible water shall be removed from the valve body and seat area. Blow dry with clean compressed air. e) Apply manufacturer approved lubricant plus 10% Cortec VpCI-329 (SAP 1000173887) added to all interior critical surfaces such as seal areas. Ball valves shall be full operated to distribute inhibited lubricant between ball and body.

Constructed Piping Hydrotest Practice (Valve Safeguards)

a) Hydrotest plans for constructed field equipment shall be designed to minimize exposure of valves to hydrotest water. Unless it is absolutely unavoidable, critical isolation valves (Field Hydrotested) shall be installed after completion of hydro. b) Piping systems shall be thoroughly flushed before hydrotesting to remove wind-blown sand, construction debris, and any other foreign matter. Flushing water shall be the same quality as the hydrotest water. Hydrotest shall be performed immediately after flushing or the line shall be properly layed-up per SAES-A-007 Procedures (30-day rule). c) If any 400 series (13 CR) trimmed valves are pre-installed & hydrotested in the line, utilize test gaskets and thoroughly drain test water immediately after the test. Where complete draining is impossible (no valve body drain plug), valves shall be removed immediately after test, dried with clean compressed air and re-lubricated before "ambient" lay-up. Ensure that there is no debris in the seat area. d) Any 400 series (13 CR) trimmed valves that are pre-installed and hydrotested in the line, and that have body or seat drains and are in place when field pipework is hydrotested shall be treated with Cortec VpCI 609 by blowing into all possible valve injection locations immediately after completion of the hydrotest and draining of all water. e) Any 400 series (13Cr) trimmed valves that are pre-installed welded-in-place shall be liberally coated with inhibited lubricant before final welding into the line. f) Safeguards for 300 series (316 SS, etc) trimmed valves require similar care to assure complete cavity draining. Corrosion inhibitors used shall be approved by CSD.

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