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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


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
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

Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)

A1

Procedure Scope Section contains a section for Quality Goals & Continuing Process Improvement, customer satisfaction, & lists quality goals (following example provided): When made evident through documentation of field deficiencies or when requested by SA, revisions to improve this document and other quality awareness corrective and preventive actions shall be taken in a Continuing Process Improvement (CPI) effort targeting Project Quality Goals such as Customer Satisfaction, reduction of costly rework, & Savings through Quality. Such Revisions shall correct errors, deficiencies, omissions or detail more thoroughly quality elements to provide adequate field instruction in an effort to meet SA Stds & Industry Best Practices for Pressure Testing. Alternative: QP covers this & regular Quality Review shall identify deficiencies for Procedural Improvement & corrective action.

Sch Q, CPI clause

A2

Procedure is project specific, identifiable by Budget Item (BI) or Job Number, Contract Number & Project title & traceable to Quality Plan.

Sch Q, Para 3.1

A3

A) An approval section exists to document adequacy prior to use. B) Revision control section exists to document procedure changes. (ISO 9001:2000, Para. 4.2.3a)

Sch Q, Para 3.1

A5

An attachment section exists listing applicable QC forms & records. (ISO 9001:2000, Para. 4.2.4a)

Sch Q, Para 3.1

A6

Other sections for special process control procedures (per Sch Q) detail references, responsibilities, definitions & procedure reqmts.

Sch Q, Para 3.1

A7

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) B) Can identify weld repairs & modifications after acceptance and any need for follow-up pressure testing or NDT. Also, backlogs. 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

SAEP-1160, Section 6 (Data Elements)

Page 1 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. B

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

General Requirements 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 flushing reqmts & safety precautions (*Use a test symbol legend) Relief valve capacity, testing and installation Pressure gages and recorders calibration records SA Safety Instruction Sheet (critical piping), Pressure Test Report Copies of P&ID & ISOs of the piping system to be pressure tested Piping spools control sheet with NDT extent and results. 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 Test medium (water, treated water, lube oil, etc) and cleanliness Test pressure duration and limitations 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) No block valves exist in the relief valve inlet or outlet Relief valve is located near test pump or medium supply Two or more calibrated pressure gauges are used (30 day rule) Pressure gauges are properly located with block/bleed valves Pressure gages at pump or supply are clearly visible to operator Blowdown & Isolation valves exist on the test piping Blowdown areas are designated for safety (Warning signs) Manifold is certified/tested to 1.2 times maximum test pressure. 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 approved pressure testing procedure shall be kept at test sites. Test crews and those personnel responsible for pressure testing are trained and aware of GI and procedural requirements to assure safe pressure testing Procedure Equipment or Safety section details regular safety inspections & maintenance of test equipment per SAIC-A-2009.

B1

SAEP-1160, Section 8 See Note 1 & SAIC-A-2003

B2

GI-2.102 Attachment 1 Section 2

B3

GI-002.102, Attachment 1, Section 5 See Note 2 & SAIC-A-2009

B4

SAES-A-004, Section 5.7

B5

See Note 2 & SAIC-A-2009

Page 2 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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. Inspection strategies & plans are prepared and 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) B) If Valve Field Testing is included in procedure (see API 598), add: Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure Test & Backseat Test (SAES-L-108, Section 4.7.6) Procedure clearly states differences between test types

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

B6

SAES-A-007, Section 5.7

B7

SAES-L-150, Section 4 See also Attachment 2

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 pipe's nominal wall. 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. B) A 24-hour recorded 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) minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors) B) Actual wall thickness & flange rating determines test pressure. Work is per latest edition of SAEP-310 requirements for the Repair & Maintenance of Pipelines. Procedure details: Valve Field Pressure Test Applications, Test Facility, & considerations before, during, and after testing:

C1

SAES-L-150, Section 8

C2

SAES-L-150, Section 8

C3

SAES-L-150, Section 8

C4 D

See item D4 below

On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs) Procedure has an On-Plot Piping Pressure Testing Matrix. See Attachment 1. This shall cover all tests for On-Plot activities and, when reviewed with the Pressure Testing Specification, shall provide adequate instruction for Test Package Development & On-Plot pressure testing & other related testing activities including all Utilities (sewer, water), Firewater & Plumbing systems. Provide clear 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 applicable SA requirements and ASME B31.3 or ASME B31.1 except as noted. (Detail Exceptions in procedure) Vessel Trim receives a strength test except for vessel trim in Utility services tested at 150 psi and less (conduct a service test). Clearly identify Vessel & Piping Code test boundary limits. Define Test Workscope & Specifications Sch Q, Att IV, Table 2.1

D1

D2

SAES-L-150, Section 5

D3

SAES-L-150, Section 5

Page 3 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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 Testing Facility meets SAIC-L-2031 (See Sections D & J). C) In-line testing of valves (body test, seat test restrictions & calcs) D) Post Test draining, cleaning, inspection and preservation details shall be included 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 the piping or equipment to which it is connected. Lube and seal oil piping is strength tested in its own fluid at the greater of 1.5 times design pressure or 100 psig (for 30 minutes). Underground process plant piping is tested as follows: A) Prior to any backfilling for 2 hours minimum (Check 100% joints) B) If back-filling is required for safety, 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 Jacketed piping exams & hydrotest sequence are detailed in the test procedure (code references apply): A) Inner lines are accepted & all exams (visual, NDE, etc) are complete & acceptable prior to strength testing internal piping. B) Inner piping joints are 100% visually accessible for pressure test C) Outer pipe split fitting design for branches allows joint access. D) Outer pipe is centered with spacers seal welded to inner pipe. Jacket material design & installation sequence meets code. E) Service testing can be performed on the outer steam piping. Detail any chart recorder use (24-hour supplemental test) Tie-In butt welds are detailed in hydrotest procedure as follows: A) Tie-in butt welds (to new or existing pipe) are strength tested B) Strength Test Pressure is based on minimum Code 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. 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 that line. 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) discharging directly to atmosphere (max internal pressure 10 psig) is not pressure tested. Test Package lists "Visual exam only".

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

D4

SAES-L-150, Section 5.11 & SAES-L-108, Section 4.7

D5 D6

SAES-L-150, Section 5 SAES-L-150, Section 7.4

D7

SAES-L-150, Section 7.4

D8

ASME B31.3, Section 345.2.5

D9

SAES-L-150, Section 5

D10

SAES-L-150, Para 5.12

D11

SAES-L-150, Section 5.8

D12

SAES-L-150, Section 5.9

Page 4 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

D13

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 GI0151.006, SA Sanitary Code, Chapter SASC-S-01. The procedure 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)

SAES-S-060, Para. 103.5.3.3

D14

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-S070, 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 less than 1- times maximum working pressure, but not less than 60 psi (413kPa) for a SAES-S-060, period of not less than thirty (30) minutes. Para. 103.5.3.3, C) A low pressure air test not exceeding 345 kPa (50 psig), & soap Para 1204.3.2, bubble test shall be used to test sanitary drainage or plumbing system of Para. 103.5.5.1 any building premises when there is reason to believe that it has become defective (damaged during 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 GI0151.006, Saudi Aramco Sanitary Code, Chapter SASC-S-01. Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-S070, 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 less than 1- times maximum working pressure, but not less than 60 psi (413kPa) for a SAES-S-060, period of not less than thirty (30) minutes. Para. 103.5.3.3, C) A low pressure air test not exceeding 345 kPa (50 psig), & soap Para 1204.3.2, bubble test shall be used to test sanitary drainage or plumbing system of Para. 103.5.5.1 any building premises when there is reason to believe that it has become defective (damaged during 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 GI0151.006, Saudi Aramco Sanitary Code, Chapter SASC-S-01.

D15

Page 5 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. E

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)

E1

In New Plants, Low pressure steel piping in water, instrument air, plant air, inert gas (Nitrogen, etc.) & steam systems operating at 150 psig or lower are Service Tested (except FW systems). 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-L110 and NDE requirements, followed by Service Test. 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: A) A request of NDT in lieu of pressure testing is processed. 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).

SAES-L-150, Section 9.3

E2

SAES-L-150, Section 9.1

E3

SAES-L-150, Section 9.2

E4

Revalidation Tests in Existing Facilities ensure test pressures are the minimum required by ASME B31.3. Actual wall thickness readings (less than 30 days old) and verified flange rating is taken into consideration when calculating the test pressure.

SAES-L-150, Section 7.5

Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)

F1

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. 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.

SAES-L-350, Section 15

F2

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 and/or SRB counts greater than 10 per ml is unacceptable. Treat test fluid to control corrosion and bacteria when applicable. Employ regular water analysis, maintain certs and records.

SAES-A-007 Section 4

F3

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 B) Lay-up per 60-day rule (14 days on exchangers) 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

SAES-A-007 Section 5

Page 6 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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) Test water pH is 10.0 to 11.0 (add approved soda ash/caustic) C) Treat test water with oxygen scavenger (4-day contact rule) D) Treat test water with biocide (14-day contact rule) and lay-up Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods Procedure can utilize SAES-A-007, Section 6 in entirety 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-up is required for non-metallic systems (e.g., PVC pipe). 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 -1C for corrosion control or as specified by proponent within 10 days after test & maintained dry. Procedure can utilize SAES-A-007, Section 7 in entirety

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

F4

SAES-A-007 Section 6

F5

SAES-A-007 Section 7

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. Note: Pressure Test diagrams can consist of the following: 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 required. The sketch lists detailed information/ratings of all 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 test sections 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. Inspectors check valve lineup & 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) B) Valves do not leakby (Successfully passed a seat closure test) C) Both sides of isolation valve have relief 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.

G1

SAES-A-004, Section 5.6

G2

SAES-A-5.5.4

G3

SAES-A-004, Para 7.3

G4

SAES-A-004, Para. 8.1.3

G5

SAES-A-004, Para 7.3 & Attachment 2

Page 7 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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) Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design 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 glasses, venturies, metering and other in-line equipment. List items in procedure and on reinstatement checklist

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

G6

SAES-L-150, Section 7.1 Attachment 2

G7

SAES-A-004 Para 7.1.4

G8

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. F) Other 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

SAES-A-004 Para 7.2

G9

Vent & Drain installations for testing purposes are as follows: A) Vents are provided at all high points in the piping system. B) Drains are provided at all low points in piping system excluding 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. Contractor 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 detection during the strength test. External coating/priming of such 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 legs (required). Inspection time may exceed test times listed in SIS sheets & Hydrotest reports (30 minute is a minimum). Inspectors shall complete inspection before tests are ended. Temporary supports & other support considerations for above ground piping installations during hydrotest are as follows: A) Where required to prevent damage to system B) As highlighted in the approved 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.

SAES-L-150, Section 6

G10

SAES-A-004 Para 5.5.1

G11

SAES-L-150, Section 7.3

G12

SAES-L-150, Para. 5.12.2

G13

SAES-L-150, Section 6

Page 8 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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 allow additional time (15 minutes average) for air bubbles trapped in 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.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

G14

SAES-A-004 Para 8.1.1

G15

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". Test water reuse is restricted to ensure cleanliness & quality

SAES-L-150, Section 11

G16

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 shall be closed & the test pump disconnected. (Use Bold Letters) Note: The isolation valve downstream of the manifold shall then be opened after the pump has been disconnected.

SAES-A-004, Para. 8.1.2

G17

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. C) Gages range for test pressures is 30 to 80% of full range. 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.

SAES-A-004 Para 7.1.5

G18

If strength test is not practical, it can be substituted with 100% RT & subject to approval by Inspection Department Mgr. for new projects. Process a request of NDT in lieu of pressure testing.

SAES-A-004, Section 5.7

Hydrotesting (Sample Package & reinstatement): (Include/reference reinstatement requirements that apply)

as referenced

H1

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) Sample SA Safety Instruction Sheet & Pressure Test Report Form 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.

SAES-L-310, Section 22

Page 9 of 30

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Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

H2

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 as instrument air tubing, check valve discs that were disconnected 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

SAES-L-310, Section 22

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 Note provides a complete detailing of all Pressure Testing Applications/Requirements for SA Projects. See Attachment 1. 1 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 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) Note 2. Sample Hydrotest Package Per SAIC-2003 2 Hydrotest Data Mgmt & Tracking Database per SAEP-1160 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)

3.

Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes all Note Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and test package 3 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) & adoption of Note Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality. This section is 4 not repeated in other "Review Procedure" type special process checklists, yet is intended for all.

Page 10 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA Projects Attachment 2 - Pressure Testing Inspection Guide REFERENCE DOCUMENTS: 1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing 2. SA General Instruction Manual GI-002.102 (July 22, 2001) Pressure Testing Safely 3. SAEP-1160 (17 July 2006) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects 4. SAES-A-004 (30 March 2005) General Requirements for Pressure Testing 5. SAES-A-007 (5 October 2005) Hydrostatic Testing Fluids and Lay-Up Procedures 6. SAES-L-108 (21 December 2005) Selection of Valves 7. SAES-L-150 (30 September, 2003) Pressure Testing of Plant Piping and Pipelines 8. SAES-L-310 (30 September, 2003) Design of Plant Piping 9. SAES-L-350 (30 September, 2003) Construction of Plant Piping 10. SAES-S-010 (31 December 2002) Sanitary Sewers 11. SAES-S-020 (30 November 2002) Industrial Drainage and Sewers 12. SAES-S-030 (August 2005) Storm Water Drainage Systems 13. SAES-S-040 (31 December 2003) Saudi Aramco Water Systems 14. SAES-S-050 (30 August 2000) Sprinkler and Standpipe Systems in Buildings 15. SAES-S-060 (28 January 2004) Saudi Aramco Plumbing Code 16. SAES-S-070 (28 September 2005) Installation of Utility Piping Systems

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 11 of 30

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Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
SYSTEM Process Piping ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series) TEST PRESS TEST CONSIDERATIONS & NOTES & DURATION
As Calculated* 30 mins (min) Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu 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 Systems

See Notes 30 mins (min)

*Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be 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 A) Process Piping B) Utility Piping

As Calculated See Notes

A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B) Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours. If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd. Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3

Flare Lines (24" & above)

See Notes 30 mins (min)

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 Air & Inert Gas (150 psig max) LP Steam (60 psig max) Weld-Plus-Ends (SAIC-A-2016) Existing Plant Piping Incl. Tie-Ins RETESTING REQMTS

See Notes 30 mins (min) SERVICE TEST & Soap Bubble Test 30 mins (min) SERVICE TEST 30 mins (min) Soap Bubble Leak Test at 5-10 psig As Calculated* 30 mins (min)

Tested to 1.5 times the differential external pressure, but not less than 15 psig. Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver Service tests and final gasket installation. Coordinate with system Service tests and construction completion. Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus between the gasket and the seal weld. It shall be examined for leaks using a soap solution. For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be 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. Systems that already passed a successful pressure test require RETEST IF subjected to new welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.

See Notes

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 PIPING

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 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 Piping Instrument Impulse Lines

EXEMPT, VISUAL EXAM

Drains, vents & piping downstream of pressure relieving devices that discharge directly to the 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. As Calculated* 30 mins (min) Whether piping or tubing, between the root isolation valve and the instrument isolation shall be 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).

Internally FBE Coated Lines

As Calculated* 30 mins (min)

For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not 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 Page 12 of 30Holiday Testing PRIOR TO pressure testing.

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping
Sampling Lines Vessel & Tank Trim (Piping) Skid-Mounted Piping (Vendor)
See Note See Note

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
Test as an integral part with the piping or equipment to which it is connected. Test separately (separate package) as required. Exemptions include sight glasses & other instruments. Strength or Service test associated piping based on service

Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are made to skid-mounted piping to correct misalignment, per 01-SAMSS-010 physical damage or any modifications in-situ, pressure test the affected spools. (exceptions noted)

FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042) See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J Test Location All new valves designated for isolation service (as specified by the Proponent) shall be See Note Field Testing of subjected to high pressure hydrostatic seat test prior to installation in line. New Valves Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure See Note Exception
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!

Exemption Procedure
(Checklist Item D4)

See Note See Note

Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated 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 SAESK-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. 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 13 of 30

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Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

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 term) is same as a hydrostatic leak test (B31.3) or proof test (B31.4) API 598 & SA Valve Pressure Testing Definitions 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 -1C 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 -1C 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. 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. Page 14 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures


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 break between systems): CS Class 150 # system (hydrotest at 450 psi, limiting factor = 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. 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 review, even after 2 errors. 4. Determine piping Pressure ratings as follows in the following code formula based on 90% SMYS (per SA): Use ASME B31.3 code formula t = PD / 2SE & SA requirement of 90% SMYS values for strength test calcs. Page 15 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures


Formula for pressure is P = t x 2S(0.9)(E) / D S = Stress Values from ASME B31.3 Table A-1 (API 5L Gr. B has a SMYS of 35,000) therefore S = 35,000 t = pipe thickness (nominal less 12.5 % mill tolerance for seamless pipe, less 0.10 for welded plate) 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.

Page 16 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. B

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

General Requirements 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 flushing reqmts & safety precautions (*Use a test symbol legend) Relief valve capacity, testing and installation Pressure gages and recorders calibration records SA Safety Instruction Sheet (critical piping), Pressure Test Report Copies of P&ID & ISOs of the piping system to be pressure tested Piping spools control sheet with NDT extent and results. 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 Test medium (water, treated water, lube oil, etc) and cleanliness Test pressure duration and limitations 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) No block valves exist in the relief valve inlet or outlet Relief valve is located near test pump or medium supply Two or more calibrated pressure gauges are used (30 day rule) Pressure gauges are properly located with block/bleed valves Pressure gages at pump or supply are clearly visible to operator Blowdown & Isolation valves exist on the test piping Blowdown areas are designated for safety (Warning signs) Manifold is certified/tested to 1.2 times maximum test pressure. 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 approved pressure testing procedure shall be kept at test sites. Test crews and those personnel responsible for pressure testing are trained and aware of GI and procedural requirements to assure safe pressure testing Procedure Equipment or Safety section details regular safety inspections & maintenance of test equipment per SAIC-A-2009.

B1

SAEP-1160, Section 8 See Note 1 & SAIC-A-2003

B2

GI-2.102 Attachment 1 Section 2

B3

GI-002.102, Attachment 1, Section 5 See Note 2 & SAIC-A-2009

B4

SAES-A-004, Section 5.7

B5

See Note 2 & SAIC-A-2009

Page 17 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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. Inspection strategies & plans are prepared and 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) B) If Valve Field Testing is included in procedure (see API 598), add: Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure Test & Backseat Test (SAES-L-108, Section 4.7.6) Procedure clearly states differences between test types

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

B6

SAES-A-007, Section 5.7

B7

SAES-L-150, Section 4 See also Attachment 2

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 pipe's nominal wall. 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. B) A 24-hour recorded 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) minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors) B) Actual wall thickness & flange rating determines test pressure. Work is per latest edition of SAEP-310 requirements for the Repair & Maintenance of Pipelines. Procedure details: Valve Field Pressure Test Applications, Test Facility, & considerations before, during, and after testing:

C1

SAES-L-150, Section 8

C2

SAES-L-150, Section 8

C3

SAES-L-150, Section 8

C4 D

See item D4 below

On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs) Procedure has an On-Plot Piping Pressure Testing Matrix. See Attachment 1. This shall cover all tests for On-Plot activities and, when reviewed with the Pressure Testing Specification, shall provide adequate instruction for Test Package Development & On-Plot pressure testing & other related testing activities including all Utilities (sewer, water), Firewater & Plumbing systems. Provide clear 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 applicable SA requirements and ASME B31.3 or ASME B31.1 except as noted. (Detail Exceptions in procedure) Vessel Trim receives a strength test except for vessel trim in Utility services tested at 150 psi and less (conduct a service test). Clearly identify Vessel & Piping Code test boundary limits. Define Test Workscope & Specifications Sch Q, Att IV, Table 2.1

D1

D2

SAES-L-150, Section 5

D3

SAES-L-150, Section 5

Page 18 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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 Testing Facility meets SAIC-L-2031 (See Sections D & J). C) In-line testing of valves (body test, seat test restrictions & calcs) D) Post Test draining, cleaning, inspection and preservation details shall be included 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 the piping or equipment to which it is connected. Lube and seal oil piping is strength tested in its own fluid at the greater of 1.5 times design pressure or 100 psig (for 30 minutes). Underground process plant piping is tested as follows: A) Prior to any backfilling for 2 hours minimum (Check 100% joints) B) If back-filling is required for safety, 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 Jacketed piping exams & hydrotest sequence are detailed in the test procedure (code references apply): A) Inner lines are accepted & all exams (visual, NDE, etc) are complete & acceptable prior to strength testing internal piping. B) Inner piping joints are 100% visually accessible for pressure test C) Outer pipe split fitting design for branches allows joint access. D) Outer pipe is centered with spacers seal welded to inner pipe. Jacket material design & installation sequence meets code. E) Service testing can be performed on the outer steam piping. Detail any chart recorder use (24-hour supplemental test) Tie-In butt welds are detailed in hydrotest procedure as follows: A) Tie-in butt welds (to new or existing pipe) are strength tested B) Strength Test Pressure is based on minimum Code 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. 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 that line. 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) discharging directly to atmosphere (max internal pressure 10 psig) is not pressure tested. Test Package lists "Visual exam only".

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

D4

SAES-L-150, Section 5.11 & SAES-L-108, Section 4.7

D5 D6

SAES-L-150, Section 5 SAES-L-150, Section 7.4

D7

SAES-L-150, Section 7.4

D8

ASME B31.3, Section 345.2.5

D9

SAES-L-150, Section 5

D10

SAES-L-150, Para 5.12

D11

SAES-L-150, Section 5.8

D12

SAES-L-150, Section 5.9

Page 19 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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 GI0151.006, SA Sanitary Code, Chapter SASC-S-01. The procedure 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 mains shall be hydrostatically tested, inspected, Pressure Tests force for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-S070, 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 (SATIP-S-040, test pressure not less than 1- times Pressure Tests for Plumbing SATIP-S-060, SATIP-S070, 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 less than 1- times

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

D13

SAES-S-060, Para. 103.5.3.3

D14

SAES-S-060, Para. 103.5.3.3, Para 1204.3.2, Para. 103.5.5.1 SAES-S-060, Para. 103.5.3.3, Para 1204.3.2, Para. 103.5.5.1

D15

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 psig or lower are Service Tested (except FW systems). 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-L110 and NDE requirements, followed by Service Test. 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: A) A request of NDT in lieu of pressure testing is processed. 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 readings (less than 30 days old) and verified flange rating is taken into consideration when calculating the test pressure.

E1

SAES-L-150, Section 9.3

E2

SAES-L-150, Section 9.1

E3

SAES-L-150, Section 9.2

E4

SAES-L-150, Section 7.5

Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)

Page 20 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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. 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 and/or SRB counts greater than 10 per ml is unacceptable. Treat 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 B) Lay-up per 60-day rule (14 days on exchangers) 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) Test water pH is 10.0 to 11.0 (add approved soda ash/caustic) C) Treat test water with oxygen scavenger (4-day contact rule) D) Treat test water with biocide (14-day contact rule) and lay-up Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods Procedure can utilize SAES-A-007, Section 6 in entirety 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-up is required for non-metallic systems (e.g., PVC pipe). 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 -1C for corrosion control or as specified by proponent within 10 days after test & maintained dry. Procedure can utilize SAES-A-007, Section 7 in entirety

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

F1

SAES-L-350, Section 15

F2

SAES-A-007 Section 4

F3

SAES-A-007 Section 5

F4

SAES-A-007 Section 6

F5

SAES-A-007 Section 7

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. Note: Pressure Test diagrams can consist of the following: 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)

G1

SAES-A-004, Section 5.6

Page 21 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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 required. The sketch lists detailed information/ratings of all 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 test sections 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. Inspectors check valve lineup & 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) B) Valves do not leakby (Successfully passed a seat closure test) C) Both sides of isolation valve have relief 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. 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) Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design 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 glasses, venturies, metering and other in-line equipment. 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. F) Other 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. B) Drains are provided at all low points in piping system excluding submarine and buried pipelines. (Dead legs are not installed) This is a Pre-Hydrotest checklist item verified by Inspection

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

G2

SAES-A-5.5.4

G3

SAES-A-004, Para 7.3

G4

SAES-A-004, Para. 8.1.3

G5

SAES-A-004, Para 7.3 & Attachment 2

G6

SAES-L-150, Section 7.1 Attachment 2

G7

SAES-A-004 Para 7.1.4

G8

SAES-A-004 Para 7.2

G9

SAES-L-150, Section 6

Page 22 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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. Contractor 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 detection during the strength test. External coating/priming of such 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 legs (required). Inspection time may exceed test times listed in SIS sheets & Hydrotest reports (30 minute is a minimum). Inspectors shall complete inspection before tests are ended. Temporary supports & other support considerations for above ground piping installations during hydrotest are as follows: A) Where required to prevent damage to system B) As highlighted in the approved 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 allow additional time (15 minutes average) for air bubbles trapped in 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". 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 shall be closed & the test pump disconnected. (Use Bold Letters) 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. C) Gages range for test pressures is 30 to 80% of full range. 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 & subject to approval by Inspection Department Mgr. for new projects. Process a request of NDT in lieu of pressure testing. Hydrotesting (Sample Package & reinstatement): (Include/reference reinstatement requirements that apply)

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

G10

SAES-A-004 Para 5.5.1

G11

SAES-L-150, Section 7.3

G12

SAES-L-150, Para. 5.12.2

G13

SAES-L-150, Section 6

G14

SAES-A-004 Para 8.1.1

G15

SAES-L-150, Section 11

G16

SAES-A-004, Para. 8.1.2

G17

SAES-A-004 Para 7.1.5

G18

SAES-A-004, Section 5.7 as referenced

Page 23 of 30

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Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA 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) Sample SA Safety Instruction Sheet & Pressure Test Report Form 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 as instrument air tubing, check valve discs that were disconnected 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

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

H1

SAES-L-310, Section 22

H2

SAES-L-310, Section 22

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 Note provides a complete detailing of all Pressure Testing Applications/Requirements for SA Projects. See Attachment 1. 1 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 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) Note 2. Sample Hydrotest Package Per SAIC-2003 2 Hydrotest Data Mgmt & Tracking Database per SAEP-1160 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)

3.

Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes all Note Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and test package 3 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) & adoption of Note Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality. This section is 4 not repeated in other "Review Procedure" type special process checklists, yet is intended for all.

ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA Projects Attachment 2 - Pressure Testing Inspection Guide REFERENCE DOCUMENTS: 1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing 2. SA General Instruction Manual GI-002.102 (July 22, 2001) Pressure Testing Safely 3. SAEP-1160 (17 July 2006) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects 4. SAES-A-004 (30 March 2005) General Requirements for Pressure Testing 5. SAES-A-007 (5 October 2005) Hydrostatic Testing Fluids and Lay-Up Procedures

Page 24 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing (All Applications)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

SAES-L-108 (21 December 2005) Selection of Valves SAES-L-150 (30 September, 2003) Pressure Testing of Plant Piping and Pipelines SAES-L-310 (30 September, 2003) Design of Plant Piping SAES-L-350 (30 September, 2003) Construction of Plant Piping SAES-S-010 (31 December 2002) Sanitary Sewers SAES-S-020 (30 November 2002) Industrial Drainage and Sewers SAES-S-030 (August 2005) Storm Water Drainage Systems SAES-S-040 (31 December 2003) Saudi Aramco Water Systems SAES-S-050 (30 August 2000) Sprinkler and Standpipe Systems in Buildings SAES-S-060 (28 January 2004) Saudi Aramco Plumbing Code SAES-S-070 (28 September 2005) Installation of Utility Piping Systems

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 25 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
SYSTEM Process Piping ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series) TEST PRESS TEST CONSIDERATIONS & NOTES & DURATION
As Calculated* 30 mins (min) Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu 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 piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig, See Notes Lube & Seal Oil whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely 30 mins (min) Systems 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 A) Process Piping B) Utility Piping

As Calculated See Notes See Notes 30 mins (min)

A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B) Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours. If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd. Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3

Flare Lines (24" & 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 Air & Inert Gas (150 psig max) LP Steam (60 psig max) Weld-Plus-Ends (SAIC-A-2016) Existing Plant Piping Incl. Tie-Ins RETESTING REQMTS

See Notes 30 mins (min) SERVICE TEST & Soap Bubble Test 30 mins (min) SERVICE TEST 30 mins (min) Soap Bubble Leak Test at 5-10 psig As Calculated* 30 mins (min)

Tested to 1.5 times the differential external pressure, but not less than 15 psig. Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver Service tests and final gasket installation. Coordinate with system Service tests and construction completion. Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus between the gasket and the seal weld. It shall be examined for leaks using a soap solution. For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be 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. Systems that already passed a successful pressure test require RETEST IF subjected to new welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.

See Notes

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 PIPING

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 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 Piping Instrument Impulse Lines

EXEMPT, VISUAL EXAM

Drains, vents & piping downstream of pressure relieving devices that discharge directly to the 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. As Calculated* 30 mins (min) Whether piping or tubing, between the root isolation valve and the instrument isolation shall be 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).

Internally FBE Coated Lines

As Calculated* 30 mins (min)

For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not 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.

Page 26 of 30

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Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping
Sampling Lines Vessel & Tank Trim (Piping) Skid-Mounted Piping (Vendor)
See Note See Note

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Test as an integral part with the piping or equipment to which it is connected. Test separately (separate package) as required. Exemptions include sight glasses & other instruments. Strength or Service test associated piping based on service

Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are made to skid-mounted piping to correct misalignment, per 01-SAMSS-010 physical damage or any modifications in-situ, pressure test the affected spools. (exceptions noted)

FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042) See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J Test Location All new valves designated for isolation service (as specified by the Proponent) shall be See Note Field Testing of subjected to high pressure hydrostatic seat test prior to installation in line. New Valves Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure See Note Exception
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!

Exemption Procedure
(Checklist Item D4)

See Note See Note

Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated 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 SAESK-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. 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 27 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

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 term) is same as a hydrostatic leak test (B31.3) or proof test (B31.4) API 598 & SA Valve Pressure Testing Definitions 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 -1C 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 -1C 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. 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. Page 28 of 30

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Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

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 break between systems): CS Class 150 # system (hydrotest at 450 psi, limiting factor = 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. 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 review, even after 2 errors. 4. Determine piping Pressure ratings as follows in the following code formula based on 90% SMYS (per SA): Use ASME B31.3 code formula t = PD / 2SE & SA requirement of 90% SMYS values for strength test calcs. Page 29 of 30

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


Review Procedure - Pressure Testing for Plant Piping

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2001

1-Dec-06

MECH-

Formula for pressure is P = t x 2S(0.9)(E) / D S = Stress Values from ASME B31.3 Table A-1 (API 5L Gr. B has a SMYS of 35,000) therefore S = 35,000 t = pipe thickness (nominal less 12.5 % mill tolerance for seamless pipe, less 0.10 for welded plate) 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.

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