SAIC-A-2001 Rev 7

SAIC NUMBER DATE APPROVED QR NUMBER
BEEA'H INSPECTION CHECKLIST

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
3414-BA-ISO-001
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)
A
Sch Q,
Procedure is project specific, identifiable by Budget Item (BI) or Job
A1
Number, Contract Number & Project title & traceable to Quality Plan.
Para 3.1, 3.2
A) An approval section exists to document adequacy prior to use.

Sch Q,
B) Revision control section exists to
A2
document procedure changes. (ISO
Para 3.1, 3.2
9001:2008, Para. 4.2.3a)
Sch Q,
An attachment section exists listing applicable QC forms & records.
A3
(ISO 9001:2008, Para. 4.2.4a)
Para 3.1, 3.2
Sch Q,
Other sections for special process control procedures (per Sch Q)
A4
detail references, responsibilities, definitions & procedure reqmts.
Para 3.1, 3.2
Special Process Procedure includes details of Data Mgmt & Tracking

system used for tracking/reporting & the responsibility for following:
A) Production
welds (full pen groove welds*), welder performance, NDE, PMI,
PWHT, BHT & other applicable tests (Ferrite Content, etc) SAEP-1160,
B) Can identify weld repairs & modifications after Section 6
acceptance and any need for follow-up pressure testing or NDT. Also,
A5
backlogs. (Data Elements)
C) Detailed steps for Pressure testing package co-ordination
with above items (controls) and pressure testing reporting
requirements.
Contractor shall record & track production,
inspection & testing of socket & fillet welds in separate database
submitted weekly to SA
Page 1 of 23
SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -March 2013) Rev 7 31-Mar-13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER


ITEM
No.
General Requirements
B Note 1: Use SAIC-A-2003 for specific Test package responsibilities & instructions
Note 2: Use SAIC-A-2009 for specific Testing Equipment requirements including Safety Inspections
Procedure lists Pressure Test Package contents as follows:

• Reference "Approved" Pressure Test Procedure
• Pressure Test Diagram* which shall include the limits of piping
(including test manifold arrangement) & equipment included in each
pressure test, high points & low points (vent, drain), locations of
pressure gauges, test pressures, test temperature, test fluid, line SAEP-1160,
flushing reqmts & safety precautions (*Use a test symbol legend) Section 8
• Relief valve capacity, testing and installation
• Pressure gages and recorders calibration records See Note 1 &
• SA Safety Instruction Sheet (critical piping), Pressure Test Report
B1
• Copies of P&ID & ISOs of the piping system to be pressure tested SAIC-
• Piping spools control sheet with NDT extent and results. A-2003
• Pre-pressure test check List
• Re-instatement procedure and Check List
• Flange set completion documentation for permanent installations
• Identification of pressure testing SPC from contractor
• Lay-up method to be applied
• Verification of chemical dosing calculations when applicable
• Test manifold hydro test verification
Procedure (elements) detail GI-2.102 reqmts as follows:

• Pressure Test Diagrams (Use of Test Symbol Legend)
• Test manifold arrangement (GI-2.102 Att. 1 Sect. 5, SAIC-A-2009)
• Location of blind flanges & isolation valves
• Check Valve & sensitive instrument/equipment disposition
• Test limiting factor determination (SIS sheet/Component review)
• Location of test vents, fill points and drains
• Relief Valve capacity, quantity, sizes and set pressure adequacy
GI-2.102
• Test medium (water, treated water, lube oil, etc) and cleanliness
B2
• Test pressure duration and limitations
Para 5.1.2.5
• Special support requirements
• Test sequence (Controlled/staged pressure rise, 10-minute holds)
• Detailed Inspection & Test Crew responsibilities
during testing
• Safeguards (Personnel clearance, Barricades, signs, permits)
• Staged and safe filling, venting and disposal practices
• Additional personnel & Equipment (radio, signals) used for tests
• Safety Instruction Sheets (Completion & Review Responsibility)
Procedure Equipment section details requirements as listed:

• Relief Valve is tested/tagged with set pressure/date (7 day rule)
• Relief valve has adequate capacity (multiple relief for volume test) GI-002.102,
• No block valves exist in the relief valve inlet or outlet Attachment 1,
• Relief valve is located near test pump or medium supply Section 5
B3 • Two or more calibrated pressure gauges are used (30 day rule)
• Pressure gauges are properly located with block/bleed valves See Note 2 &
• Pressure gages at pump or supply are clearly visible to operator SAIC-A-
• Blowdown & Isolation valves exist on the test piping 2009
• Blowdown areas are designated for safety (Warning signs)
• Manifold is certified/tested to 1.2 times maximum test pressure.
Page 2 of 23


ITEM
No.
Procedures for both hydrotests and service tests address safety

precautions provided in GI-0002.102 "Pressure Testing Safely".
Procedure states: A copy of GI-2.102 and the
SAES-A-004,
B4 approved pressure testing procedure shall be kept at test sites. Test
Section 5.6, 5.7
crews and those personnel responsible for pressure testing are
trained and aware of GI and procedural requirements to assure safe
pressure testing
Procedure states: Hydrostatic tests are scheduled as close as

possible to start-up date with minimal time between introducing test
water & commissioning the equipment. Hydrostatic tests and lay-up
procedure shall be designed to protect corrosion-susceptible matls. SAES-A-007,
B5 Section 4.3.1,
Inspection strategies & plans are prepared and 4.4
agreed on prior to commencing fabrication and erection. System
testing & lay-up considerations shall be addressed (SAES-L-350,
Para. 17.2)
Definitions of various types of pressure tests are listed:
A) Hydrostatic Test, Leak Test, Pneumatic Test, Revalidation Test,
Service Test, Strength Test, Tightness Test (SAES-L-150, Sect. 4)
SAES-L-150,
B) If
Section 4
Valve Field Testing is included in procedure (see API 598), add:
B6
See also
Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure
Attachment 2
Test & Backseat Test (SAES-L-108, Section 4.7.6)
Procedure clearly states differences between test
types
C Pipeline Pressure Testing Applications (Include in procedure if applicable per scope)
Pipeline Strength Tests for New Pipelines are detailed in

procedure and conducted as follows:
A) Strength Test pressure is limited by flanges or
valves in the line.
B) Strength Test pressure is calculated. Hoop
Stress (HS) at 90% of Specified Minimum Yield Strength (SMYS) of
SAES-L-150,
C1 pipe's nominal wall.
Section 8
C) Strength Test pressure at low point considers static head
D) Strength test temperature stresses are not above
SMYS.
E) Strength test pressure is maintained for two hours.
Procedure details calculation checks
and responsibilites
Pipeline Tightness Test is conducted at 95% strength test pressure

immediately after completion of strength test:
A) The tightness test pressure is maintained
as long as required for the inspector to examine all exposed joints.
SAES-L-150,
C2 B) A 24-hour recorded
Section 8
tightness test is done when a pipeline is buried/insulated, or
partially buried/insulated for more than 300 m or 10% of its total
length, whichever is less.
Procedure details Tightness Test parameters
Revalidation Pressure Tests for Existing Pipelines are detailed in

procedure and calculations are checked as follows:
A) Test pressure is
determined (as applicable) as follows:
• minimum of 1.25 times MAOP (with 0.6 & 0.72 design factors) SAES-L-150,
C3
• minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors) Section 8
B) The flange rating shall be taken into consideration when
calculating the test pressure. Work is per latest edition of SAEP-
310 requirements for the Repair & Maintenance of Pipelines.
Page 3 of 23


ITEM
No.
Procedure details: Valve Field Pressure Test Applications, Test SAES-L-150,

C4 Facility, & considerations before, during, and after testing: Section 5 Para
5.11
On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
D
Procedure has an On-Plot Piping Pressure Testing Matrix.

Define Test
See Attachment 1. This shall cover all tests for On-Plot
Workscope
activities and, when reviewed with the Pressure Testing
&
Specification, shall provide adequate instruction for Test Package
D1 Specifications
Development & On-Plot pressure testing & other related testing
Sch
activities including all Utilities (sewer, water), Firewater &
Q, Att IV, Table
Plumbing systems. Provide clear
2.1
On-Plot test boundaries & test reqmts.
Procedure states: A hydrostatic strength test shall be applied to

all newly constructed plant piping prior to initial operation per the SAES-L-150,
D2
applicable SA requirements and ASME B31.3 or ASME B31.1 except Section 5.3
as noted. (Detail Exceptions in procedure)
Procedure details: Valve Pressure Test Applications, Test

Facility, & considerations before, during, and after testing:
A) Applications include Field hydrotesting per
SAIC-L-2042 that follow SAES-L-108, API 598, & ASME B16.34
requirements. Valves require body & seat closure tests per SAES-L-
108, Sect. 4. B) Valve SAES-L-150,
Testing Facility meets SAIC-L-2031 (See Sections D & J). Section 5.11
D3 C) In-line testing of valves (body test, seat &
test restrictions & calcs) D) Post Test draining, SAES-L-108,
cleaning, inspection and preservation details shall be included Section 4.7
whenever valves without drains are tested in-line.
Valve Testing is included in pressure
testing procedure. See Att 2 (API 598 Definitions, Considerations
for Tests against Valve Seats, Post-Test Valve cavity cleaning &
inspection)
Sampling piping systems are pressure tested as an integral part of

SAES-L-150,
D4 the piping or equipment to which it is connected.
Section 5
SAES-L-150,
Lube and seal oil piping is strength tested in its own fluid at the
D5 Section 7
greater of 1.5 times design pressure or 100 psig (for 30 minutes).
Para 7.5.1
Underground process plant piping is tested as follows:
A) Prior to any backfilling for 2 hours

minimum (Check 100% joints) SAES-L-150,
D6
B) If back-filling is required for safety, Section 7.5.2
there are two options:
• 100% of weld joints remain fully exposed during the 2 hour test
• 24-hour recorded test is performed if any weld joint is buried
Page 4 of 23


ITEM
No.
For jacketed piping, the internal line shall be hydrotested according

to paragraph 7.1. All field welds shall be visible for leak detection
during the hydrotest. Thejacket shall be hydrotested according to
SAES-L-150
D7 ASME B31.3. The maximum allowable external pressure for the
Para 7.4
internal line shall not be exceeded during the jacket pressure test.
The differential pressure can be minimized by pressurizing the
internal line.
Tie-In butt welds are detailed in hydrotest procedure as follows:

A) Tie-in butt welds (to new or
existing pipe) are strength tested
SAES-L-150,
D8 B) Strength Test Pressure is based on minimum Code
Section 5
requirements if the tie-in is to an existing system.
C) If a strength test is deemed impractical, it can be substituted with
a request of NDT in lieu of pressure testing as processed.
Instrument impulse lines are hydrotested only as follows:
A) Liquid test is performed when the test pressure is greater than
1000 psig. Air or nitrogen use is allowed up to 1000 psig.
B) Between root isolation valve & instrument isolation using treated

water (or approved fluid) at 1.25 times system design pressure.
SAES-L-150,
D9
Para 5.12
C) The test duration is not less than 30 minutes.
D) Instrumentation subject to damage from testing is disconnected.
E) When liquid is used in lieu of air,
lines are blown dry after test. See
Attachment 2 for related Flushing/Cleaning Methods
RETESTING of Piping systems that have already successfully

passed a pressure test require a second pressure test if/when:
A) Major Repair of Piping system subject to new
welding activity. Note: This includes
modifications & pressure boundary work.
B) Post-weld Heat Treatment (PWHT) is specified for
SAES-L-150,
D10 that line.
Section 5.8
Note: Seal welded threaded connections, non-pressure containing
welds to attachments (wear pads, etc) are exempt from retesting
unless the line is specified for PWHT.
Procedure details retesting reqmts &
responsibilities, and the Database has capability for tracking
such repairs.
Open-ended Piping (drains, vents & piping downstream of PZVs)

SAES-L-150,
D11 discharging directly to atmosphere (max internal pressure 10 psig) is
Section 5.9
not pressure tested. Test Package lists "Visual exam only".
Page 5 of 23


ITEM
No.
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060) are

detailed in procedure as follows:
A) Test entire hot or cold water supply system
(test & prove tight) under a water pressure of 1034 kPa (150 psig) for
4 hrs minimum. Note 1: Test all piping
within building from building isolation valve.
Note 2: Water distribution piping network (utility piping from
tankage) to building isolation valve & connected fire hydrants are
tested at 150 psig or 50 psig above maximum operating pressure,
whichever is greater.
Newly
constructed water supply systems are disinfected per GI- SAES-S-060,
D12 0151.006, SA Sanitary Code, Chapter SASC-S-01. The procedure Para. 103.5.3.3
covers this as part of preparation (treatment)
B) Service Test (Check for leaks) shall be performed on
all new equipment connected to water supply lines such as Water
Heaters, Drinking Fountains, etc. that are isolated from the 150 psi
test. 6.3 Testing, Inspection and Backfilling
Gravity sanitary sewers, gravity sanitary sewer manholes and
sanitary sewer force mains shall be hydrostatically tested,
inspected, repaired and backfilled in
accordance with SAES-S-070. 8-2.2
(Addition) Disposal of water used for flushing and testing
the piping system shall be in accordance with GI-0432.000.
(rescinded)
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

S-070, SATIP-S-020) are detailed in procedure as follows:
A) Test entire hot or
cold water supply system (test & prove tight) under a water pressure
of 1034 kPa (150 psig) for 4 hrs minimum.
B) Test Gas Systems (welds & joints accessible)
with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not SAES-S-060,
less than 1-½ times maximum working pressure, but not less than 60 Para. 103.5.3.3,
psi (413kPa) for a period of not less than thirty (30) minutes. Para
D13 C) A low pressure air test not exceeding 1204.3.2,
345 kPa (50 psig), & soap bubble test shall be used to test sanitary
drainage or plumbing system of any building premises when there is Para.
reason to believe that it has become defective (damaged during 103.5.5.1
construction). D) Service Tests
(Gravity Tests) shall be performed on all lines. newly constructed,
have been repaired or have otherwise become
contaminated, shall be thoroughly disinfected in accordance with GI-
0151.006,
Saudi Aramco Sanitary Code, Chapter SASC-S-01.
Page 6 of 23


ITEM
No.
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

S-070, SATIP-S-020) are detailed in procedure as follows:
A) Test entire hot or
cold water supply system (test & prove tight) under a water pressure
of 1034 kPa (150 psig) for 4 hrs minimum.
B) Test Gas Systems (welds & joints accessible)
with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not SAES-S-060,
less than 1-½ times maximum working pressure, but not less than 60 Para. 103.5.3.3,
psi (413kPa) for a period of not less than thirty (30) minutes. Para
D14 C) A low pressure air test not exceeding 1204.3.2,
345 kPa (50 psig), & soap bubble test shall be used to test sanitary
drainage or plumbing system of any building premises when there is Para.
reason to believe that it has become defective (damaged during 103.5.5.1
construction). D) Service Tests
(Gravity Tests) shall be performed on all lines. newly constructed,
have been repaired or have otherwise become
contaminated, shall be thoroughly disinfected in accordance with GI-
0151.006,
Saudi Aramco Sanitary Code, Chapter SASC-S-01.
E Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)
In New Plants, Low pressure steel piping in water, instrument air,

plant air, inert gas (Nitrogen, etc.) & steam systems operating at 150
SAES-L-150,
E1 psig or lower are Service Tested (except FW systems).
Section 9.3
Vessel Trim & Sampling lines also receive a Service
test.
Service Test After Minor Leak Repairs (in Existing Facilities) is

detailed as follows in the procedure (as applicable per scope):
A) When small diameter threaded piping (in all services/pressures)
repairs are made, thread engagement and seal welding meets SAES-L-150,
E2
SAES-L-110 and NDE requirements, followed by Service Test. Section 9.1
Seal weld repairs are not done

on Sch. 40 galvanized joints
Service Test socket welded piping on Tie-in work & repairs (in
Existing Facilities) if Operations Engineering Unit determines
hydrostatic test is impractical & the following requirements are met:
SAES-L-150,
E3 A) A request of NDT in lieu of pressure testing is processed.
Section 9.2
B) Qualified welders and welding procedures are used.
C) Weld gap is verified & welding is witnessed by Operations Insp.
D) Welds are MT or PT tested (Operations Inspection choice).
Revalidation Tests in Existing Facilities ensure test pressures are

the minimum required by ASME B31.3. Actual wall thickness
SAES-L-150,
E4 readings (less than 30 days old) and verified flange rating is taken
Section 7.6
into consideration when calculating the test pressure.
F Pressure Testing of Hot Tap & Stopple Connection
Procedure* & Design Package* for Hot Taps & Stoppling Connection
Use
F1 Install.
SAIC-L-2090
Note: * Use latest Edition SAEP-311 (Safety).
Page 7 of 23


ITEM
No.
Use
F2 Hot Tap/Stopple & Reinforcement Calculation Request-Form 7627
SAIC-L-2091
Pressure Testing (Hot Tap Installation)

a) Header + hot tap fitting or sticker(prior to repad installation)
Use
F3 b) Header+hot tap fitting+hot tap valve
SAIC-L-2095
c) Header+hot tap fitting+valve+hot tap machine (HOT TAP
APPLICATION)
Pressure Testing (Stopple Installation)

a) Header+Stopple fitting+hot tap valve (if used)
Use
F4 b) Header+Equalizing nipple+specialty fitting
SAIC-L-2095
c) Stopple fitting+hot tap valve/Sandwich valve+hot tap machine
(STOPPLING APPLICATION)
G Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)
Assembled piping is cleaned/flushed per procedure prior to testing:

A) Water & Pneumatic flushing (SAES-L-350 App. A) See Att # 2
B) Pressurized Air Shock Blowing (PASB) per SAES-L-350 App. A
C) By a Pre-job agreed upon procedure accepted by Company (SA)
PMT, Proponent & Inspection representatives.
SAES-L-350,
G1
Section 15
See Attachment # 2. Cleaning and flushing methods are
incorporated into the procedure & test packages. Valve cavity
(low point) draining, drying, cleaning & reinspection measures
shall be detailed where no low point drains exist.
The general flushing medium is plant/ process water or raw water.

Fire water may be used where process water is not available. Sea
water is not acceptable. Water for hydrostatic test with pH less than 6
SAES-A-007
G2 and/or SRB counts greater than 10² per ml is unacceptable. Treat
Section 4
test fluid to control corrosion and bacteria when applicable.
Employ regular water analysis,
maintain certs and records.
Test Procedure details Lay-up & treatment of Hydrostatic Test Water

for Carbon & Low Alloy Steel systems as follows:
A) Follow 14-day rule with oxygen scavenger & 90-day rule with
biocide use in pipelines, use batching scrapers & nitrogen slug to
separate air from contacting treated water
SAES-A-007
G3 B) Lay-up per 60-day rule (14 days on exchangers)
Para 5.2
• Wet, Dry, Inert Gas & Ambient Methods are detailed in procedure
• Boiler Layup is per SAEP-1026, Other methods are CSD approved
Procedure can utilize SAES-A-007, Section 5 in entirety
Test Procedure details Lay-up & treatment of Hydrostatic Test Water

for Stainless (300, 400 series) systems as follows:
A) Chloride content of test water is tested/certified below 50 mg/L.
B) Treat test water with oxygen scavenger (4-day contact rule) SAES-A-007
G4
C) Treat test water with biocide (14-day contact Section 6
rule) and lay-up
• Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods
Page 8 of 23


ITEM
No.
Special Test preparation requirements are met as follows:

A) Carbon steel atmospheric storage tanks are tested with
plant water (untreated) with all traces of water removed after the test.
B) Potable water system test water is treated with chlorine or sodium
hypochlorite for disinfection (with dry or ambient lay-up).
C) Water is
untreated for completely internally coated/lined systems and no lay-
SAES-A-007
G5 up is required for non-metallic systems (e.g., PVC pipe).
Section 7
D) For Dry Gas & Refined Hydrocarbon Product Pipelines,
oxygen scavenger is added to test water, use batching scrapers &
nitrogen slug to separate contacting treated water (Plant piping
exempt)
• Lay-up by drying to dew point of -1°C for corrosion control or as
specified by proponent within 10 days after test & maintained dry.
H Detailed Pressure Testing Procedure Requirements (Include applicable requirements)
Hydrotest (Pressure Test) Diagrams and procedures include the

limits of piping (including test manifold) and equipment included in
each hydrostatic test, test pressures, test temperature, test fluid, line
flushing requirements, and safety precautions.
SAES-A-004,
H1 Note: Pressure Test diagrams can consist of the following:
Section 5.6
• Marked P&IDs & Isometric drawings that use test symbol legend
• Copies of Manifold sketches and manifold test certificates.
• Procedure can allow multiple circuit testing (show jumper hoses)
Test manifolds are certified & tested to 1.2 times maximum test
pressure but not less than discharge pressure of test pump.
Manifold Test Report (Sketch & Certificate) is SAES-A-004
H2
required. The sketch lists detailed information/ratings of all Para 5.5.4
components. Manifolds receive unique numbers and records are
kept.
Procedure details isolation of test sections (checklist items):
A) Paddle blinds or
spectacle blinds isolate test sections.
B) Blind flanges, pipe plugs and caps isolate
SAES-A-004,
H3 test sections
Para 8.3
C) Block valve isolation is severely restricted & supported by
calcs. Fabricated test
implements are rated, marked & inspected
During the application of the test pressure, all in-line valves if not
used as test isolation valves are verified to be in an open position. SAES-A-004,
H4
Inspectors check valve lineup Para. 9.1.3
& position prior to testing.
Block valve use for isolation during hydrotest (testing against the seat
of a closed gate, ball or plug valve) is limited & supported with
Engineering calculations (limiting factor considerations) as follows:
A) Test pressures never
exceed seat closure test pressures per API 598 (Example: 150# gate
valve seat closure test is at 314 psi) SAES-A-004,
B) Valves do not Para 8.3 &
H5 leakby (Successfully passed a seat closure test)
C) Both sides of isolation valve have relief Attachment 2
valves during test.
D) Test pressure is never reduced below 1.5 x
system design pressure per SAES-L-150, Section 7 (ASME B31.3,
Para. 345.4.2) Ensure testing
against valve seats causes no damage.
Page 9 of 23


ITEM
No.
Limiting Factors (test pressures on SIS Sheets/Test Report Forms)
are reviewed by Engineering & verified by Inspection as follows:
• Hoop stress in pipe (nominal wall less mill tolerance) of 90% of
Specified Minimum Yield Strength (SMYS) at test temperature.
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
• Valve pressure rating (1.5xASME B16.34 value, round up 25) SAES-L-150,
H6 • Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design Section 7.1
Attachment 2
• Internal FBE Coating pressure rating is known, listed & considered
Ensure limiting factors are listed (SIS Sheets/test reports)
Prevent overpressurization & damage! See Excel Sheet 3
Components in new piping systems that interfere with filling,

venting, draining or flushing are not installed until after line flushing &
pressure testing are complete. (orifice plates, flow nozzles, sight SAES-A-004
H7
glasses, venturies, metering and other in-line equipment. Para 8.1.4
List items in procedure and on
reinstatement checklist
Sensitive Equipment excluded from Pressure Test is listed:

A) Rotating machinery, such as pumps, turbines and compressors;
B) Strainers and filter elements
C) Pressure relieving devices (rupture disks & relief valves)
D) Installed system gages where test pressure will exceed range
E) Equipment that cannot be drained & Instrument Devices.
SAES-A-004
H8 F) Other
Para 8.2
sensitive equipment designated by SA Inspector*
*Soft seated valves & control valves are installed
AFTER lines have been thoroughly flushed (SAES-A-004 Para
7.1.3)
List items in procedure and on reinstatement
checklist
Vent & Drain installations for testing purposes are as follows:
A) Vents are provided at all high points in the
piping system.
SAES-L-150,
H9 B) Drains are provided at all low points in piping system excluding
Section 6
submarine and buried pipelines. (Dead legs are not installed)
This is a
Pre-Hydrotest checklist item verified by Inspection
Relief valves of adequate capacity are set to relieve at 5% above test
pressure. Relief valve(s) are tested, dated, and tagged within one
week prior to the hydrotest for new construction projects.
SAES-A-004
H10 Contractor
Para 5.5.1
maintains list of relief valves and has a SA approved vendor or
system to do weekly calibrations. Inspectors witness relief valve
calibrations
All joints (threaded, welded & flanged) are exposed for visual leak
SAES-L-150,
H11 detection during the strength test. External coating/priming of such
Section 7.3
joints is not allowed unless approved by ID Manager & Proponent
Test duration and hold times consider full inspection access via
scaffolding & manlifts as necessary to allow visual inspection of
100% of all joints including weep holes, 6mm drain holes in dummy
SAES-L-150,
H12 legs (required). Inspection time may exceed test times listed in SIS
Para. 7.2
sheets & Hydrotest reports (30 minute is a minimum).
Inspectors shall complete inspection before tests
are ended.
Page 10 of 23


ITEM
No.
Temporary supports & other support considerations for above ground
piping installations during hydrotest are as follows:
A) Where
required to prevent damage to system
SAES-L-150,
H13 B) As highlighted in the approved
Section 6
hydrotesting procedure. C)
Expansion joints and spring hangers or spring supports are to be
provided with temporary restraints where needed to prevent
excessive travel or deformation under test loads.
Filling & pressurization is done upstream of check valves in system.

Test fluid enters & drains at lowest points to minimize trapped air.
All vents are open during filling.
Procedure contains the following:
Note: Filling a system too quickly frequently
results in air trapped within the system. This accounts for test
failures and delay due to noticeable pressure drops. Test crews shall SAES-A-004
H14
allow additional time (15 minutes average) for air bubbles trapped in Para 9.1.1
test water to vent. After such time & fluid levels drop at vents, a final
slow fill is done. Justification
for Note: Thousands of manhours are lost due to test failures
until steps are taken to adequately train test crews to stop
rushing during filling, assure adequate time for proper venting
of air & use a slow final fill technique.
Disposal sites for the test fluid shall be reviewed and approved prior
to the hydrostatic test in accordance with SAEP-327 "Disposal of
Wastewater from Cleaning, Flushing, and Hydrostatic Tests". SAES-L-150,
H15
Section 11
Test water reuse is restricted to ensure cleanliness &
quality
After the test pressure is reached and before commencement of

inspection of the system, the isolation valve between the temporary
test manifold/piping and the piping/equipment under pressure test SAES-A-004,
H16
shall be closed & the test pump disconnected. (Use Bold Letters) Para. 9.1.2
Note: The isolation valve downstream of the manifold
shall then be opened after the pump has been disconnected.
Pressure gages & recorder requirements are listed as follows:

A) Calibration intervals do not exceed one (1) month.
B) Stickers (signed by Inspection) show latest calibration
date.
SAES-A-004
H17 C) Gages range for test pressures is 30 to 80% of full range.
Para 8.1.5
D) Two gages (accuracy of each within 5%) are used in testing.
E) When large systems are
tested, additional gages are required. A
current list of gauges (records) & cal due dates are kept.
If strength test is not practical, it can be substituted with 100% RT &

SAES-A-004,
H18 subject to approval by Inspection Department Mgr. for new projects.
Section 6
Process a request of NDT in lieu of pressure testing.
Hydrotesting (Sample Package & reinstatement):

I (Include/reference reinstatement as referenced
requirements that apply)
Page 11 of 23


ITEM
No.
Test procedure details test package contents as follows:

• Sample Hydrostatic Test Diagram (see 8.01 above)
• Sample Pre-Hydrotest Checklist (sensitive equipment, line flushing)
• Sample Relief Valve Data Sheets & Calibration Records
• Sample Pressure gage & recorders calibration records
• Sample Test Manifold Test Records (1.2 x maximum pressure)
SAES-L-310,
I1 • Sample SA Safety Instruction Sheet & Pressure Test Report Form
Section 22
• Sample copy of P&IDs used (test boundaries & symbols)
• Sample copy of Isometrics used (test boundaries & symbols)
• Sample Piping Spools Control Sheet with NDT extent & Result
• Sample Inspection & Test Plan Sheet (sign offs)
• Sample Re-instatement Check list (Re-instatement is in procedure)
Provide sample test package & procedure for SA approval.
Removal of Test Components and reinstatement of items after

pressure testing is addressed in the procedure as follows:
A) All
temporary items installed for testing purposes (manifolds, valves,
blinds, spacers, gaskets, supports, etc) are removed.
B) Components that interfered with system
filling/venting/draining & Sensitive Equipment (removed before
testing) are reinstalled. C) Items such SAES-L-310,
I2
as instrument air tubing, check valve discs that were disconnected Section 22
before testing shall be reconnected.
D) Isolation valves closed for test purposes
required to be in the open position for process reasons shall be
opened. E) If the valve
cavity has a drain, the cavity shall be drained. Test procedure details
test package contents as follows:
Procedure references and details the reinstatement effort
REMARKS:
Pressure Test Procedure (SAES-A-004 Definition): Information assembled to ensure all requirements listed in GI-0002.102 , all
referenced SA & Industrial standards are met. Per SAES-A-004 Definition, test packages are part of the Pressure Test Procedure. This
checklist provides a complete detailing of all Pressure Testing Applications/Requirements for SA Projects. See Attachment 1.
Note
Hydrotest, Pneumatic and Soap Bubble Leak Test*,
Service Test, & Valve Testing, can be one (1) procedure (Pressure Testing). Small projects (less than 500 welds) do not require a
1
Database for tracking welds & test packages per SAEP-1160 requirements. *Note: Soap Bubble Leak Test
procedure (See SAIC-A-2005) shall meet ASME SEC V Article 10 & Appendix requirements.
Pressure Test Plan is submitted for Company review & contains the following 4 elements necessary to control the work:
1. Pressure Test Procedure (Including Test Package Controls)
2. Sample Hydrotest
Note
Package Per SAIC-2003 3. Hydrotest Data Mgmt
& Tracking Database per SAEP-1160
2
Small projects (less than 500 welds) do not require a Database for tracking welds & test packages per SAEP-1160 requirements.
4. Pressure Testing Specification (Plant Piping System Line Class List
modified for Pressure test design)
Note Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes
all Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and test
3 package development. Submit early on major projects as Pressure Testing is almost always Critical Path on Projects.
Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) &
Note
adoption of Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality.
This section is not repeated in other "Review Procedure" type special process checklists, yet is intended for all.
4
Page 12 of 23


ITEM
No.
ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA Projects
Attachment 2 - Pressure Testing Inspection Guide
Page 13 of 23


ITEM
No.
REFERENCE DOCUMENTS:
1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing (Project Specific)
2. SA General Instruction Manual GI-002.102 (28 October 2008) Pressure Testing Safely
3. SAEP-1160 (10 July 2011) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects
4. SAES-A-004 (30 Jan 2011) General Requirements for Pressure Testing
5. SAES-A-007 (24 July 2011) Hydrostatic Testing Fluids and Lay-Up Procedures
6. SAES-L-108 (11 Oct 2010) Selection of Valves
7. SAES-L-150 (25 April 2010) Pressure Testing of Plant Piping and Pipelines
8. SAES-L-310 (25 July 2012) Design of Plant Piping
9. SAES-L-350 (22 April 2009) Construction of Plant Piping
10. SAES-S-010 (21 November 2009) Sanitary Sewers
11. SAES-S-020 (13 March 2011) Industrial Drainage and Sewers
12. SAES-S-030 (16 March 2011) Storm Water Drainage Systems
13. SAES-S-040 (10 March 2012) Saudi Aramco Water Systems
14. SAES-S-050 (29 Aug 2012) Sprinkler and Standpipe Systems in Buildings
15. SAES-S-060 (2 March 2013) Saudi Aramco Plumbing Code
16. SAES-S-070 (5 Dec 2012) Installation of Utility Piping Systems
17. SAEP-311 (13 September 2009) Installation of Hot Tapped and Stopple Connections (Use Latest Edition for Safety)
AAMCO BEEA'H
Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED
Page 14 of 23
SAUDI ARAMCO ID/PID - REV 0- 18-May-05(Standards Cutoff -March 2013) Rev 7 31-Mar-13
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 30-Apr-13 MECH-
Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)
SYSTEM TEST PRESS TEST CONSIDERATIONS & NOTES
&
Process DURATION
As Calculated* Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test
30 mins (min) required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu
Piping of pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process
requests per Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.
*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of new
constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below.
Lube & Seal Oil See Notes *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100
30 mins (min) psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be
Systems completely cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints
Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged and
threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the joints
(check low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.
Underground As Calculated A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B)
A) Process See Notes Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.
Piping If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd.
B) Utility Piping
Flare Lines See Notes Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength
30 tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & mins (min)
above)
Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less than
24 inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5 psig in lieu
of a high pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc when
requested by Company. Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.
Vacuum Piping See Notes Tested to 1.5 times the differential external pressure, but not less than 15 psig.
30
mins (min)
Air & Inert Gas SERVICE TEST & Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded
(150 psig Soap Bubble Test joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and
max) 30 Receiver Service tests and final gasket installation.
mins (min)
LP Steam SERVICE TEST Coordinate with system Service tests and construction completion.
(60 psig max) 30 mins (min)
Weld-Plus-Ends Soap Bubble Leak Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus
(SAIC- Test at 5-10 psig between the gasket and the seal weld. It shall be examined for leaks using a soap solution.
A-2016)
Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required by
Piping 30 mins (min) the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be
Incl. Tie-Ins determined and taken into consideration when calculating the test pressure. In case of flanged
tie-in connections, a flange tester is utilized to conduct hydrostatic testing of flange butt weld.
RETESTING See Notes Systems that already passed a successful pressure test require RETEST IF subjected to new
REQMTS welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE
RETEST UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).
REPAIR EXISTING See Notes Every existing plant piping & pipeline, after repairs or alterations have been made that affect the
integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test
PIPING pressure shall be in accordance with the requirements of the applicable code.
Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc
Open-Ended EXEMPT, Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
Piping VISUAL EXAM atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc
Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined.
Instrument As Calculated* Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
Impulse Lines 30 mins (min) pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or
process equipment to which it is connected. Test duration shall not be less than 30 minutes.
Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater
than 1000 psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).
Page 15 of 23
Internally FBE As Calculated* For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not
Coated Lines 30 mins (min) exceed 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System
Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.
Sampling Lines See Note Test as an integral part with the piping or equipment to which it is connected.
Vessel & Tank See Note Test separately (separate package) as required. Exemptions include sight glasses &
Trim other instruments. Strength or Service test associated piping based on service
(Piping)
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test
Skid-Mounted EXEMPT IF TESTED BY 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
Piping (Vendor) VENDOR per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct
(exceptions misalignment, physical damage or any modifications in-situ, pressure test the
noted) affected spools.
FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042)
Test Location See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Field Testing of See Note All new valves designated for isolation service (as specified by the Proponent) shall
be subjected to high pressure hydrostatic seat test prior to installation in line.
New Valves
Exception See Note Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!
Exemption See Note Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt
Procedure See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be equal
to those that the valves were originally purchased to. All resilient (soft) seated
(Checklist Item D4)
isolation valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a
unique ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique
ID & corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg &
Database (Piping System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl
Receipt Inspection (internal visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions &
follow-up preservation reqmts) & segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.
SPECIFIC TESTING REQUIREMENT SUMMARY (ALL SA APPLICATIONS PER SAES-L-150, Section 6)

6.1 Plant Piping - Pressure testing of On-Plot Plant Piping shall be per SAES-L-150. See Section D of this Checklist.
6.2 Cross-Country Pipelines - Pressure testing of cross country pipelines shall be per SAES-L-150. See Section C of this Checklist.
6.3 Pressure Vessels - Hydrostatic testing for new vessels (shop or field fab) shall be conducted as follows:
ASME Section VIII, D1 to SAMSS-004, Para 16.3.8.1. & ASME Section VIII, D2 to 32-SAMSS-004, Para 16.3.8.2
Hydrostatic testing for existing vessels shall be conducted per SAES-D-008, Paragraph 10.1.
Pneumatic test as approved by Insp Dept Mgr (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2)
6.4 Heat Transfer Equipment - Hydrostatic tests for existing equipment shall be per SAES-D-008.
For pneumatic testing, refer to same as above for Vessels (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2)
Boilers receiving Hydrostatic test (new, field fabricated boilers) shall be in accordance with 32-SAMSS-021.
Boiler pressure test After Repair or Alteration, refer to SAES-D-008 & National Board Insp Code, NB-23.
Boiler Hydrostatic test during T&Is shall be per test pressure as specified on boiler's safety instruction sheet.
Heater Tube (coil) Assy Hydrostatic test for new, field fabricated heater tube assembly shall be per 32-SAMSS-029.
Heat Exchanger Tube bundles removed from X-chgr (maintenance) get in-situ shell side test per SAES-D-108 prior to return to service
Fin Fan X-chgr is strength tested (as stamped) in-situ prior to final acceptance (new project), & whenever transported.
6.5 Tanks - For new, field fabricated tanks, & existing tanks, hydrostatic testing shall be per 32-SAMSS-006 for large, low pressure welded
tanks; or 32-SAMSS-005 for atmospheric steel tank, as applicable.
6.6 Fire Protection Systems - Pressure test new & existing fire protection systems (SAES-B-017, GI-1781.001).
6.7 Refrigerant Piping Systems - Refrigerant piping serving building air conditioning systems shall be tested according to the requirements of
SAES-K-001 and the Uniform Mechanical Code (UMC), Section 1520.
6.8 Potable Water Systems - Potable water piping inside buildings shall be tested per the reqmts of Uniform Plumbing Code (UPC).
Exceptions to UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS
Potable water piping outside of buildings shall be tested per the requirements of SAES-S-040
(SAES-S-070, Section 18).
6.9 Utility Piping Systems - Utility systems, including irrigation piping & water distribution mains, shall be tested per SAES-S-070, Sect 18
6.10 Industrial Drainage and Sewers - Industrial drainage and sewers shall be tested per SAES-S-020 (SAES-070, Section 18).
6.11 Sanitary Sewers - Sanitary sewer systems within buildings shall be tested per reqmts of the Uniform Plumbing Code (UPC).
Exceptions to UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS
Sanitary sewer lines outside of buildings shall be tested in accordance with SAES-S-070 Section 18.
6.12 Storm Water Drainage Systems - Test per SAES-S-030 (SAES-S-070, Section 18) Note: Only OWS portions are tested.
Page 16 of 23
6.13 Miscellaneous Building Services Piping - Steam & condensate piping outside the jurisdiction of ASME B31.3, heating & cooling water
piping, vacuum & compressed air system piping for building services shall be tested per ASME B31.9, Building Services Piping.
6.14 Gas Cylinders - Gas cylinders shall be tested per Saudi Aramco Bottled Gas Manual. (Application - New Labs, etc)
6.15 Valves - Valves shall be tested in accordance with SAES-L-108, Section 4.7
6.16 Non Metallic Piping - Such as RTR, Thermoplastic, PVC/UPVC & CPVC shall be tested per SAES-S-070, Section 18.
Page 17 of 23
Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
SAES-L-150 Pressure Testing Definitions
Hydrostatic Test: A pressure test conducted using water or other approved liquid as the test medium.
Leak Test: A pressure test to ensure tightness of flanged and threaded joints at the test
pressure. It is normally conducted before initial start-up & after T&Is. A leak test is different from tightness test
below.
Pneumatic Test: A pressure test conducted using air or other approved gas as the test medium or in conjunction
with liquid.
Revalidation Test: A pressure test performed to prove the integrity of existing pipelines or plant piping.
Service Test: A pressure test performed to prove the integrity of pipelines or plant piping using the service fluid at
the maximum attainable operating pressure.
Strength Test: A pressure test at an internal pressure determined in accordance with this standard and the
applicable Code* to verify the integrity of the piping systems for service at the design pressure.
Tightness Test: Pressure test to ensure piping system tightness (i.e., no system leaks) at
test pressure.
*Strength test (ASME B31.8 code APIterm)
598 is
& same
SA Valve
as aPressure Testing
hydrostatic Definitions
leak test (B31.3) or proof test (B31.4)
Shell (Body Hydrostatic) Test: A pressure test conducted using water or other approved liquid as the test
medium and applying pressure inside the assembled valve with the valve ends closed, the valve partially open &
any packing gland tight enough to maintain test pressure, thus testing the stuffing box.
High-Pressure Closure (Hydrostatic Seat) Test: A pressure test
conducted using water or approved liquid where pressure is applied successively to each side of the closed valve
with the other side open to atmosphere to check for leaks (measured in drops) at the atmospheric side of the
closure.
Low-Pressure Closure (Pneumatic Seat) Test: A pressure test conducted using air (5 psig unless specified
otherwise) where the pressure is applied successively to each side of the closed valve (Flare system valves) with
the other side open to atmosphere to check for leaks (measured in bubbles) at the atmospheric side of the
closure. SAES-L-350 Appendix A (Cleaning Procedures)
Pneumatic flushing with dry air (dew point -1°C or less) or steam with a minimum exit velocity of 15 m/s. Repeat
flushing until cleanliness is verified by observing an absence of any solids impact on a polished metal target at
exit.
Pressurized Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an
alternative method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems
removing trapped liquid in the piping, or to verify cleanliness of small bore pipe where video inspection is
impossible or inadequate due to pipe dimension or configuration. Air shocking pressure shall never exceed
working pressure of the system and shall never be more than 810 kPa (115 psi). Safety precaution shall be
considered in consultation with Area Loss Prevention Division when this method is used. Repeat PASB until
cleanliness is verified by observing the absence of any solids impact on a polished metal target (mirror) at the exit.
Install double filters on air compressors & frequently drain water accumulation to ensure air quality & prevent
fouling of piping systems and instrumentation.
Water Flushing: Equipment sensitive to damage during water flushing shall be removed, blocked off or isolated.
A list shall be prepared and be part of the flushing procedure. Ball valves shall be flushed in fully open position. All
piping systems shall be flushed using high pressure [60.8 mPa (8.8 ksi) minimum] jet such as rotating hose or
rotating nozzle. Below 4", use High Velocity Water Flushing (HVWF). On systems where high pressure jet flushing
cannot be used due to complicated shapes and/or long runs use HVWF or slug flushing. Water velocity shall be a
minimum of 3 m/s. General flushing medium shall be plant/process/raw water. Fire water is used where process
water is not available. Sea water is not acceptable. When flushing stainless steel lines, chloride ion content shall
be less than 50 mg/L. After flushing, piping systems shall be completely drained, dried to a dew point below -1°C
and protected against corrosion. Valve Cavities (low points) without drains shall be addressed in the
procedure.
Mechanical Scrapers: Can be used under the condition that damage to the pipe interior surface shall not occur.
Page 18 of 23
Valve Considerations: Valve Cavities (low points) without drains shall be addressed in the test procedure.
Whenever any valve without a low point drain is tested in-line, steps shall be taken to assure:
1) Complete draining of low points including the valve cavity after testing.
2) Complete removal of debris deposited during flushing and filling. Demonstrate
effectiveness of flushing to prevent debris accumulation in low points. Reinspection after cleaning and
examination of seating surfaces & performance of manufacturer recommended preservation or corrosion control
measures is one acceptable method. Contact CSD.
3) Corrosion Protection measures shall be per SAES-A-007. Ambient lay-up of 400* Series (13Cr) trim
valves, (Trim 1, 4, 6, 7, 8 & 8A) is prohibited without CSD approved corrosion prevention measures.
TEST WITH ISOLATION AGAINST VALVE SEATS (CALCS) PER SAES-A-004, SECTION 7.3
Example 1: A typical Carbon Steel Class 150 # system (Proposed for hydrotest at 450 psi, limiting factor = flange)
1. A test proposes isolatation against a closed valve (gate, ball or plug type). Valve has passed a body & seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 150 # steel gate valve (Refer to ASME B16.34, Group 1.1 Materials tables & Section 7 Pressure Testing & API
598 Table 3 & Table 4) has working pressure design rating of 285 psi.
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (285 x 1.5 = 427.5 = 450 psi)
• Determine Valve Seat/Closure Test pressure. Design = 110% or 1.1 per API 598 Table 3 (285 x 1.1 = 313.5 psi).
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 1 minute (valves to 12” NPS)
Do not allow a 30 minute hydrotest at 450 psi against the valve seat (because overpressurization results).
Resolution: Remove valve from line for test, install a 150# blind flange & proceed with test at 450 psi Or, reduce
test pressure to 313 psi & list valve seat closure as ""limiting factor"" if valve cannot* be removed for test
(*justification
Example #2 (Spec& Company
break approval is required)CS Class 150 # system (hydrotest at 450 psi, limiting factor =
between systems):
flange).
1. Test limit is at a 24” Class 300 # Ball Valve (spec break). Proposed test against valve in closed position. Valve
passed body/seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 300 # steel ball valve (ASME B16.34, Group 1.1 Matls table & API 598 Tables 3 & 4) has working pressure
design rating of 740 psi
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (740 x 1.5 = 1,110 = 1125 psi)
• Determine Valve Seat/Closure Test value. Design x 110% or 1.1 per API 598 Table 3 (740 x 1.1 = 814 psi)
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 2 minutes (valves 14” NPS & over)
Result: Allow 30 minute hydro at 450 psi. Isolation valve is a Higher Class (No seat overpressurization).
LIMITING FACTOR CALCS (PREVENT OVERPRESSURIZATION & POTENTIAL DAMAGE)
Inspectors: Upon receipt of test packages for new systems, Inspectors always review test packages (SIS Sheets
& Test Reports) for errors regarding limiting factor. An organized system of checks takes only minutes per
package.
• Reduce test pressures for metallurgy such as SS, CuNi, Ductile Iron (flanges, valves)
• Reduce test pressures for system limiting factors (flanges, valves, piping of large diameters, internal coatings)
Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are reviewed by Engineering & checked for:
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
• Valve pressure rating (1.5xASME B16.34 value, round up 25)
• Hoop stress in pipe (nom. wall less mill tolerance) of 90% of Specified Min. Yield Strength (SMYS) at test temp
• Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design & considers internal coating maximum
allowable service pressure (SAES-H-102 APCS system 100, 101, 103 = 5,000 psi --- APCS 102 = 3,000 psi)
Ensure limiting factors are listed (SIS Sheets/test reports) and are correct per SAES-L-150, Section 7.1
Example #1: A CS 150 # Raw Water System 12LEOU (hydrotest at 450 psi per SIS, limiting factor = flange)
System has Fusion-bonded epoxy (FBE) internally coated piping & valves (check & gate) for corrosive water
service.
System (ISOs & SIS information match) Design Pressure = 190 psi at Design temperature of 100F. Piping is
shown on drawings to be API 5L, Gr B seamless pipe 24” Standard or .375” nominal wall, also 12” Standard or .
375” Pipe flanges are ASTM A 105, forged CS, per ASME 16.5. A 150 # gate valve in this service is Ductile iron
ASTM A395 epoxy lined body, Bolted Bonnet, ASTM B61/B62 bronze trim. A 150 # check valve in this service is
Ductile iron ASTM A395 epoxy lined body, Bolted Cover, ASTM B61/B62 bronze trim. Note: The system test will
cover three open gate valves, one check valve (internals removed for test), and one closed gate valve.
Page 19 of 23
Quick Calc Steps: 1. Do not accept a test in 150# system against a closed 150# valve (typical for all classes)
Do not accept the proposed test against a closed gate valve. Perform thorough review even after finding an error.
2. Determine Flange Pressure ratings as follows:
• Pipe flg limiting factor per ASME B16.5 (Table 1-A, Mat'l Group 1.1 = ASTM A 105) Press Temp Rating Table 2-
1.1
• Working pressure rating for Class 150 systems @ temp of 100 F = 285 psig (multiply value by 1.5 per Section
8.3)
• 285 x 1.5 = 427.5, round up to next increment of 25 = 450 psig (acceptable, as our listed limiting factor is 450
psi)
3. Determine Valve Pressure ratings by checking ASME B16.34 OR API 598 Table 2 & 3
Note: Class 150 Ductile Iron = 400 psig per Table 2 (shell test) & 250 psig (high
pressure seat closure test)
ACTIONS: Do not accept 450 psig test pressure. Class 150 valves (ductile iron) are tested to 400 psig (250 at
seat). B) Request a test pressure reduction to 400 psig and test limit revision & proceed with
Formula for pressure
review, even is P = t x 2S(0.9)(E) / D
after 2 errors.
S
4. =Determine
Stress Values
pipingfrom ASMEratings
Pressure B31.3asTable A-1 in
follows (API
the5L Gr. B has
following a SMYS
code formulaof based
35,000)
ontherefore
90% SMYS S = (per
35,000
SA):
tUse
= pipe
ASMEthickness (nominal
B31.3 code less t12.5
formula = PD%/ mill
2SEtolerance for seamless
& SA requirement of pipe, less 0.10”
90% SMYS for welded
values plate) test calcs.
for strength
Therefore .375” x 87.5%, t = .328” for both 12” & 24” seamless pipe
P = unknown & E = Quality Factor from Table A-1A or Table A-1B (Quality factor for API 5L Seamless Pipe is
1.00), therefore E = 1.00
D = outside diameter of piping (all sizes are considered in calcs), therefore 2 calcs will be performed, one for 24”
and the other for 12”
Calc for 12” pipe ... P=.328 x (2)(35,000)(0.9) / 12 = 1,722.66 or 1,723 psi is rating for limiting factor for 12”
pipe
Calc for 24” pipe ... P=.328 x (2)(35,000)(0.9) / 24 = 861.33 or 861 psi is rating for limiting factor for 24” pipe
Notice how pipe diameter affects pressure! Neither pipe size is near our 400 psi limiting factor
5.Check FBE internal coating spec (APCS 101) indicates pressure rating of 5,000 psi per SAES-H-002, not a
factor!
ACTION: Review Complete. Return test package to Engineering. Test pressure and arrangement are
unacceptable: 1. Test pressure of 450 psig is unacceptable as Ductile Iron Valves are rated for 400
psig.
2. Use of a closed ductile iron valve at test limits is unacceptable.
Recommendation: Reduce Test pressure to 400 psig. Test valves in open position with blind at test limit.
Page 20 of 23
Attachment 3 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
OVER PRESSURIZATION ALERT FOR LATERALS
1. 100% HOLD POINT ON LATERAL BRANCH CONNECTION WELDS FOR COMPANY

VISUAL EXAMINATION OF ROOT ID. MEANS OF VISUAL EXAM MUST BE PROVIDED
(EXTENSION MIRROR / REMOTE VIDEO). USE WINDOW TECHNIQUE FOR ROOT EXAM
2. LATERALS MUST RECEIVE NDE ON
ANY EXISTING / SUSPECT ROOT CONDITIONS TO PREVENT POSSIBILITY OF FAILURE
DURING PRESSURE TESTING. 3. FULL ENCIRCLEMENT
SLEEVES MUST REINFORCE ALL LATERALS.
4. LESSONS LEARNED (HAWIYEH FATALITY) ... NEVER ALLOW
LATERALS ON ANY SYSTEM ABOVE CLASS 150# ... CALCS PER ASME B31.3 Appendix
H apply. Do not allow overpressurization. See acceptable detail below. Angle may vary.
Page 21 of 23
OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)
Page 22 of 23
Page 23 of 23

SAIC-A-2001 Rev 7

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

SAIC-A-2001 Rev 7

Загружено:

Авторское право:

Доступные форматы

SAIC NUMBER DATE APPROVED QR NUMBER

BEEA'H INSPECTION CHECKLIST

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

A) An approval section exists to document adequacy prior to use.

Special Process Procedure includes details of Data Mgmt & Tracking

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

Procedure lists Pressure Test Package contents as follows:

Procedure (elements) detail GI-2.102 reqmts as follows:

Procedure Equipment section details requirements as listed:

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

Procedures for both hydrotests and service tests address safety

Procedure states: Hydrostatic tests are scheduled as close as

C Pipeline Pressure Testing Applications (Include in procedure if applicable per scope)

Pipeline Strength Tests for New Pipelines are detailed in

Pipeline Tightness Test is conducted at 95% strength test pressure

Revalidation Pressure Tests for Existing Pipelines are detailed in

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

Procedure details: Valve Field Pressure Test Applications, Test SAES-L-150,

Procedure has an On-Plot Piping Pressure Testing Matrix.

Procedure states: A hydrostatic strength test shall be applied to

Procedure details: Valve Pressure Test Applications, Test

Sampling piping systems are pressure tested as an integral part of

Underground process plant piping is tested as follows:

A) Prior to any backfilling for 2 hours

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

For jacketed piping, the internal line shall be hydrotested according

Tie-In butt welds are detailed in hydrotest procedure as follows:

B) Between root isolation valve & instrument isolation using treated

RETESTING of Piping systems that have already successfully

Open-ended Piping (drains, vents & piping downstream of PZVs)

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060) are

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

In New Plants, Low pressure steel piping in water, instrument air,

Service Test After Minor Leak Repairs (in Existing Facilities) is

Seal weld repairs are not done

Revalidation Tests in Existing Facilities ensure test pressures are

F Pressure Testing of Hot Tap & Stopple Connection

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 30-Apr-13 MECH-

INTERNAL NATURAL GAS DISTRIBUTION LINE TO BEEA' AAMCO

Pressure Testing (Hot Tap Installation)

Pressure Testing (Stopple Installation)

Assembled piping is cleaned/flushed per procedure prior to testing:

The general flushing medium is plant/ process water or raw water.

Test Procedure details Lay-up & treatment of Hydrostatic Test Water

• Boiler Layup is per SAEP-1026, Other methods are CSD approved

Procedure can utilize SAES-A-007, Section 5 in entirety

Test Procedure details Lay-up & treatment of Hydrostatic Test Water

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER