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EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)
A
Sch Q,
Procedure is project specific, identifiable by Budget Item (BI) or Job
A1
Number, Contract Number & Project title & traceable to Quality Plan.
Para 3.1
Sch Q,
An attachment section exists listing applicable QC forms & records.
A3
(ISO 9001:2000, Para. 4.2.4a)
Para 3.1
Sch Q,
Other sections for special process control procedures (per Sch Q)
A4
detail references, responsibilities, definitions & procedure reqmts.
Para 3.1
Page 1 of 21
SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008) Rev 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
General Requirements
B Note 1: Use SAIC-A-2003 for specific Test package responsibilities & instructions
Note 2: Use SAIC-A-2009 for specific Testing Equipment requirements including Safety Inspections
Page 2 of 21
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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Procedure states: Hydrostatic tests are scheduled as close as
possible to start-up date with minimal time between introducing test
water & commissioning the equipment. Hydrostatic tests and lay-up
procedure shall be designed to protect corrosion-susceptible matls.
SAES-A-007,
B5
Para 4.3.1
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)
SAES-L-150,
B) If
Section 4
Valve Field Testing is included in procedure (see API 598), add:
B6
See also
Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure
Attachment 2
Test & Backseat Test (SAES-L-108, Section 4.7.6)
Procedure clearly states differences between test
types
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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
D
Lube and seal oil piping is strength tested in its own fluid at the SAES-L-150,
D5
greater of 1.5 times design pressure or 100 psig (for 30 minutes). Section 7.4
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SAIC NUMBER DATE APPROVED QR NUMBER
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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-
S-070, SATIP-S-020) are detailed in procedure as follows:
A) Test entire hot or
cold water supply system (test & prove tight) under a water pressure
of 1034 kPa (150 psig) for 4 hrs minimum.
B) Test Gas Systems (welds & joints accessible)
with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not SAES-S-060,
less than 1-½ times maximum working pressure, but not less than 60 Para. 103.5.3.3,
psi (413kPa) for a period of not less than thirty (30) minutes. Para
D14 C) A low pressure air test not exceeding 1204.3.2,
345 kPa (50 psig), & soap bubble test shall be used to test sanitary
drainage or plumbing system of any building premises when there is Para.
reason to believe that it has become defective (damaged during 103.5.5.1
construction). D) Service Tests
(Gravity Tests) shall be performed on all lines. newly constructed,
have been repaired or have otherwise become
contaminated, shall be thoroughly disinfected in accordance with GI-
0151.006,
Saudi Aramco Sanitary Code, Chapter SASC-S-01.
E Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)
F Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)
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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Page 7 of 21
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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
During the application of the test pressure, all in-line valves if not
Block
used as valve
testuse for isolation
isolation valves during hydrotest
are verified to be(testing against
in an open the seat SAES-A-004,
position.
G4 of a closed gate, ball or plug valve) is limited & supported withlineup
Inspectors check valve Para. 8.1.3
Engineering
& position priorcalculations (limiting factor considerations) as follows:
to testing.
A) Test pressures never
exceed seat closure test pressures per API 598 (Example: 150# gate
SAES-A-004,
valve seat closure test is at 314 psi)
Para 7.3 &
B) Valves do not
G5 leakby (Successfully passed a seat closure test)
Attachment 2
C) Both sides of isolation valve have relief
valves during test.
Limiting Factors (test pressures
D) Test on SIS
pressure Sheets/Test
is never reducedReport
below Forms)
1.5 x
are
systemreviewed
designbypressure
Engineering & verified by Section
per SAES-L-150, Inspection as follows:
7 (ASME B31.3,
•Para.
Hoop345.4.2)
stress in pipe (nominal wall less mill tolerance) of 90%
Ensure of
testing
Specified Minimum
against valve seatsYield Strength
causes (SMYS) at test temperature.
no damage.
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
• Valve pressure rating (1.5xASME B16.34 value, round up 25) SAES-L-150,
G6 • Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design Section 7.1
Attachment 2
• Internal FBE Coating pressure rating is known, listed & considered
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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
All joints (threaded, welded & flanged) are exposed for visual leak
SAES-L-150,
G11 detection during the strength test. External coating/priming of such
Section 7.3
joints is not allowed unless approved by ID Manager & Proponent
Test duration and hold times consider full inspection access via
scaffolding & manlifts as necessary to allow visual inspection of
100% of all joints including weep holes, 6mm drain holes in dummy
SAES-L-150,
G12 legs (required). Inspection time may exceed test times listed in SIS
Para. 5.12.2
sheets & Hydrotest reports (30 minute is a minimum).
Temporary supports
Inspectors& other support
shall considerations
complete inspection forbefore
abovetests
ground
piping installations during hydrotest are as follows:
are ended.
A) Where
required to prevent damage to system
Filling & pressurization is done upstream of check valves in system. SAES-L-150,
G13 B) As highlighted in the approved
Test fluid enters & drains at lowest points to minimize trapped air. Section 6
hydrotesting procedure. C)
All vents are open during filling.
Expansion joints and spring hangers or spring supports are to be
Procedure contains the following:
provided with temporary restraints where needed to prevent
Note: Filling a system too quickly frequently
excessive travel or deformation under test loads.
results in air trapped within the system. This accounts for test
failures and delay due to noticeable pressure drops. Test crews shall SAES-A-004
G14
allow additional time (15 minutes average) for air bubbles trapped in Para 8.1.1
test water to vent. After such time & fluid levels drop at vents, a final
slow fill is done. Justification
for Note: Thousands of manhours are lost due to test failures
until steps are taken to adequately train test crews to stop
rushing during
Disposal sites forfilling,
the testassure adequate
fluid shall time for
be reviewed andproper venting
approved prior
of air &
to the use a slow
hydrostatic testfinal fill technique.
in accordance with SAEP-327 "Disposal of
Wastewater from Cleaning, Flushing, and Hydrostatic Tests". SAES-L-150,
G15
Section 11
Test water reuse is restricted to ensure cleanliness &
quality
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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Page 10 of 21
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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
REMARKS:
Pressure Test Procedure (SAES-A-004 Definition): Information assembled to ensure all requirements listed in GI-0002.102 , all
referenced
Pressure TestSA &Plan
Industrial standards
is submitted are met. Per
for Company SAES-A-004
review & containsDefinition, test 4packages
the following elementsare part of the
necessary Pressure
to control theTest Procedure. This
work:
checklist provides a complete detailing of all Pressure Testing Applications/Requirements
1. Pressure Test for SA Projects.
Procedure See Test
(Including Attachment
Package 1.Controls)
Note
Hydrotest, Pneumatic and Soap Bubble LeakHydrotest
2. Sample Test*,
Note Service Test, & Valve Testing, can be one (1) procedure (Pressure Testing). Small projects (less than 500 welds) do not require a
1 Package Per SAIC-2003 3. Hydrotest Data Mgmt
Database
& Tracking forDatabase
tracking welds & test packages per SAEP-1160 requirements.
per SAEP-1160 *Note: Soap Bubble Leak Test
2 procedure (See SAIC-A-2005) shall meet ASME SEC V Article 10 & Appendix requirements.
Small projects (less than 500 welds) do not require a Database for tracking welds & test packages per SAEP-1160 requirements.
4. Pressure Testing Specification (Plant Piping System Line Class List
modified for Pressure test design)
Note Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes
all Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and test
3 package development. Submit early on major projects as Pressure Testing is almost always Critical Path on Projects.
Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) &
Note
adoption of Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality.
This section is not repeated in other "Review Procedure" type special process checklists, yet is intended for all.
4
REFERENCE DOCUMENTS:
1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing (Project Specific)
2. SA General Instruction Manual GI-002.102 (28 October 2008) Pressure Testing Safely
3. SAEP-1160 (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 (3 July 2007) Hydrostatic Testing Fluids and Lay-Up Procedures
6. SAES-L-108 (21 December 2005) Selection of Valves
7. SAES-L-150 (16 May 2007) Pressure Testing of Plant Piping and Pipelines
8. SAES-L-310 (29 April 2007) 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 (6 December 2006) Industrial Drainage and Sewers
12. SAES-S-030 (7 October 2007) Storm Water Drainage Systems
13. SAES-S-040 (31 December 2003) Saudi Aramco Water Systems
14. SAES-S-050 (27 January 2007) Sprinkler and Standpipe Systems in Buildings
15. SAES-S-060 (28 January 2004) Saudi Aramco Plumbing Code
16. SAES-S-070 (13 Novemebr 2007) Installation of Utility Piping Systems
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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Dec-09 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Contractor / Third-Party Saudi Aramco
Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)
SYSTEM TEST PRESS TEST CONSIDERATIONS & NOTES
&
Process DURATION
As Calculated* Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test
30 mins (min) required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu
Piping of pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process
requests per Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.
*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of new
constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below.
Lube & Seal Oil See Notes *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100
30 mins (min) psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be
Systems completely cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints
Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged and
threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the joints
(check low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.
Underground As Calculated A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B)
A) Process See Notes Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.
Piping If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd.
B) Utility Piping
Flare Lines See Notes Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength
30 tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & mins (min)
above)
Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less than
24 inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5 psig in lieu
of a high pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc when
requested by Company. Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.
Vacuum Piping See Notes Tested to 1.5 times the differential external pressure, but not less than 15 psig.
30
mins (min)
Air & Inert Gas SERVICE TEST & Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded
(150 psig Soap Bubble Test joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and
max) 30 Receiver Service tests and final gasket installation.
mins (min)
LP Steam SERVICE TEST Coordinate with system Service tests and construction completion.
(60 psig max) 30 mins (min)
Weld-Plus-Ends Soap Bubble Leak Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus
(SAIC- Test at 5-10 psig between the gasket and the seal weld. It shall be examined for leaks using a soap solution.
A-2016)
Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required by
Piping 30 mins (min) the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be
Incl. Tie-Ins determined and taken into consideration when calculating the test pressure. In case of flanged
tie-in connections, a flange tester is utilized to conduct hydrostatic testing of flange butt weld.
RETESTING See Notes Systems that already passed a successful pressure test require RETEST IF subjected to new
REQMTS welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE
RETEST UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).
REPAIR EXISTING See Notes Every existing plant piping & pipeline, after repairs or alterations have been made that affect the
integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test
PIPING pressure shall be in accordance with the requirements of the applicable code.
Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc
Open-Ended EXEMPT, Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
Piping VISUAL EXAM atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc
Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined.
Instrument As Calculated* Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
Impulse Lines 30 mins (min) pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or
process equipment to which it is connected. Test duration shall not be less than 30 minutes.
Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater
than 1000 psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).
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Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
Internally FBE As Calculated* For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not
Coated Lines 30 mins (min) exceed 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System
Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.
Sampling Lines See Note Test as an integral part with the piping or equipment to which it is connected.
Vessel & Tank See Note Test separately (separate package) as required. Exemptions include sight glasses &
Trim other instruments. Strength or Service test associated piping based on service
(Piping)
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test
Skid-Mounted EXEMPT IF TESTED BY 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
Piping (Vendor) VENDOR per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct
(exceptions misalignment, physical damage or any modifications in-situ, pressure test the
noted) affected spools.
FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042)
Test Location See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Field Testing of See Note All new valves designated for isolation service (as specified by the Proponent) shall
be subjected to high pressure hydrostatic seat test prior to installation in line.
New Valves
Exception See Note Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!
Exemption See Note Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt
Procedure See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be equal
to those that the valves were originally purchased to. All resilient (soft) seated
(Checklist Item D4)
isolation valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a
unique ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique
ID & corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg &
Database (Piping System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl
Receipt Inspection (internal visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions &
follow-up preservation reqmts) & segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.
6.12 Storm Water Drainage Systems - Test per SAES-S-030 (SAES-S-070, Section 18) Note: Only OWS portions are tested.
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Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
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.
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Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 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 APIterm)
598 is
& same
SA Valve
as aPressure Testing
hydrostatic Definitions
leak test (B31.3) or proof test (B31.4)
Shell (Body Hydrostatic) Test: A pressure test conducted using water or other approved liquid as the test
medium and applying pressure inside the assembled valve with the valve ends closed, the valve partially open &
any packing gland tight enough to maintain test pressure, thus testing the stuffing box.
High-Pressure Closure (Hydrostatic Seat) Test: A pressure test
conducted using water or approved liquid where pressure is applied successively to each side of the closed valve
with the other side open to atmosphere to check for leaks (measured in drops) at the atmospheric side of the
closure.
Low-Pressure Closure (Pneumatic Seat) Test: A pressure test conducted using air (5 psig unless specified
otherwise) where the pressure is applied successively to each side of the closed valve (Flare system valves) with
the other side open to atmosphere to check for leaks (measured in bubbles) at the atmospheric side of the
closure. SAES-L-350 Appendix A (Cleaning Procedures)
Pneumatic flushing with dry air (dew point -1°C or less) or steam with a minimum exit velocity of 15 m/s. Repeat
flushing until cleanliness is verified by observing an absence of any solids impact on a polished metal target at
exit.
Pressurized Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an
alternative method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems
removing trapped liquid in the piping, or to verify cleanliness of small bore pipe where video inspection is
impossible or inadequate due to pipe dimension or configuration. Air shocking pressure shall never exceed
working pressure of the system and shall never be more than 810 kPa (115 psi). Safety precaution shall be
considered in consultation with Area Loss Prevention Division when this method is used. Repeat PASB until
cleanliness is verified by observing the absence of any solids impact on a polished metal target (mirror) at the exit.
Install double filters on air compressors & frequently drain water accumulation to ensure air quality & prevent
fouling of piping systems and instrumentation.
Water Flushing: Equipment sensitive to damage during water flushing shall be removed, blocked off or isolated.
A list shall be prepared and be part of the flushing procedure. Ball valves shall be flushed in fully open position. All
piping systems shall be flushed using high pressure [60.8 mPa (8.8 ksi) minimum] jet such as rotating hose or
rotating nozzle. Below 4", use High Velocity Water Flushing (HVWF). On systems where high pressure jet flushing
cannot be used due to complicated shapes and/or long runs use HVWF or slug flushing. Water velocity shall be a
minimum of 3 m/s. General flushing medium shall be plant/process/raw water. Fire water is used where process
water is not available. Sea water is not acceptable. When flushing stainless steel lines, chloride ion content shall
be less than 50 mg/L. After flushing, piping systems shall be completely drained, dried to a dew point below -1°C
and protected against corrosion. Valve Cavities (low points) without drains shall be addressed in the
procedure.
Mechanical Scrapers: Can be used under the condition that damage to the pipe interior surface shall not occur.
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SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
Valve Considerations: Valve Cavities (low points) without drains shall be addressed in the test procedure.
Whenever any valve without a low point drain is tested in-line, steps shall be taken to assure:
1) Complete draining of low points including the valve cavity after testing.
2) Complete removal of debris deposited during flushing and filling. Demonstrate
effectiveness of flushing to prevent debris accumulation in low points. Reinspection after cleaning and
examination of seating surfaces & performance of manufacturer recommended preservation or corrosion control
measures is one acceptable method. Contact CSD.
3) Corrosion Protection measures shall be per SAES-A-007. Ambient lay-up of 400* Series (13Cr) trim
valves, (Trim 1, 4, 6, 7, 8 & 8A) is prohibited without CSD approved corrosion prevention measures.
TEST WITH ISOLATION AGAINST VALVE SEATS (CALCS) PER SAES-A-004, SECTION 7.3
Example 1: A typical Carbon Steel Class 150 # system (Proposed for hydrotest at 450 psi, limiting factor = flange)
1. A test proposes isolatation against a closed valve (gate, ball or plug type). Valve has passed a body & seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 150 # steel gate valve (Refer to ASME B16.34, Group 1.1 Materials tables & Section 7 Pressure Testing & API
598 Table 3 & Table 4) has working pressure design rating of 285 psi.
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (285 x 1.5 = 427.5 = 450 psi)
• Determine Valve Seat/Closure Test pressure. Design = 110% or 1.1 per API 598 Table 3 (285 x 1.1 = 313.5 psi).
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 1 minute (valves to 12” NPS)
Do not allow a 30 minute hydrotest at 450 psi against the valve seat (because overpressurization results).
Resolution: Remove valve from line for test, install a 150# blind flange & proceed with test at 450 psi Or, reduce
test pressure to 313 psi & list valve seat closure as ""limiting factor"" if valve cannot* be removed for test
(*justification
Example #2 (Spec& Company
break approval is required)CS Class 150 # system (hydrotest at 450 psi, limiting factor =
between systems):
flange).
1. Test limit is at a 24” Class 300 # Ball Valve (spec break). Proposed test against valve in closed position. Valve
passed body/seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 300 # steel ball valve (ASME B16.34, Group 1.1 Matls table & API 598 Tables 3 & 4) has working pressure
design rating of 740 psi
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (740 x 1.5 = 1,110 = 1125 psi)
• Determine Valve Seat/Closure Test value. Design x 110% or 1.1 per API 598 Table 3 (740 x 1.1 = 814 psi)
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 2 minutes (valves 14” NPS & over)
Result: Allow 30 minute hydro at 450 psi. Isolation valve is a Higher Class (No seat overpressurization).
LIMITING FACTOR CALCS (PREVENT OVERPRESSURIZATION & POTENTIAL DAMAGE)
Inspectors: Upon receipt of test packages for new systems, Inspectors always review test packages (SIS Sheets
& Test Reports) for errors regarding limiting factor. An organized system of checks takes only minutes per
package.
• Reduce test pressures for metallurgy such as SS, CuNi, Ductile Iron (flanges, valves)
• Reduce test pressures for system limiting factors (flanges, valves, piping of large diameters, internal coatings)
Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are reviewed by Engineering & checked for:
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
• Valve pressure rating (1.5xASME B16.34 value, round up 25)
• Hoop stress in pipe (nom. wall less mill tolerance) of 90% of Specified Min. Yield Strength (SMYS) at test temp
• Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design & considers internal coating maximum
allowable service pressure (SAES-H-102 APCS system 100, 101, 103 = 5,000 psi --- APCS 102 = 3,000 psi)
Ensure limiting factors are listed (SIS Sheets/test reports) and are correct per SAES-L-150, Section 7.1
Example #1: A CS 150 # Raw Water System 12LEOU (hydrotest at 450 psi per SIS, limiting factor = flange)
System has Fusion-bonded epoxy (FBE) internally coated piping & valves (check & gate) for corrosive water
service.
System (ISOs & SIS information match) Design Pressure = 190 psi at Design temperature of 100F. Piping is
shown on drawings to be API 5L, Gr B seamless pipe 24” Standard or .375” nominal wall, also 12” Standard or .
375” Pipe flanges are ASTM A 105, forged CS, per ASME 16.5. A 150 # gate valve in this service is Ductile iron
ASTM A395 epoxy lined body, Bolted Bonnet, ASTM B61/B62 bronze trim. A 150 # check valve in this service is
Ductile iron ASTM A395 epoxy lined body, Bolted Cover, ASTM B61/B62 bronze trim. Note: The system test will
cover three open gate valves, one check valve (internals removed for test), and one closed gate valve.
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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
Quick Calc Steps: 1. Do not accept a test in 150# system against a closed 150# valve (typical for all classes)
Do not accept the proposed test against a closed gate valve. Perform thorough review even after finding an error.
2. Determine Flange Pressure ratings as follows:
• Pipe flg limiting factor per ASME B16.5 (Table 1-A, Mat'l Group 1.1 = ASTM A 105) Press Temp Rating Table 2-
1.1
• Working pressure rating for Class 150 systems @ temp of 100 F = 285 psig (multiply value by 1.5 per Section
8.3)
• 285 x 1.5 = 427.5, round up to next increment of 25 = 450 psig (acceptable, as our listed limiting factor is 450
psi)
3. Determine Valve Pressure ratings by checking ASME B16.34 OR API 598 Table 2 & 3
Note: Class 150 Ductile Iron = 400 psig per Table 2 (shell test) & 250 psig (high
pressure seat closure test)
ACTIONS: Do not accept 450 psig test pressure. Class 150 valves (ductile iron) are tested to 400 psig (250 at
seat). B) Request a test pressure reduction to 400 psig and test limit revision & proceed with
Formula for pressure
review, even is P = t x 2S(0.9)(E) / D
after 2 errors.
S
4. =Determine
Stress Values
pipingfrom ASMEratings
Pressure B31.3asTable A-1 in
follows (API
the5L Gr. B has
following a SMYS
code formulaof based
35,000)
ontherefore
90% SMYS S = (per
35,000
SA):
tUse
= pipe
ASMEthickness (nominal
B31.3 code less t12.5
formula = PD%/ mill
2SEtolerance for seamless
& SA requirement of pipe, less 0.10”
90% SMYS for welded
values plate) test calcs.
for strength
Therefore .375” x 87.5%, t = .328” for both 12” & 24” seamless pipe
P = unknown & E = Quality Factor from Table A-1A or Table A-1B (Quality factor for API 5L Seamless Pipe is
1.00), therefore E = 1.00
D = outside diameter of piping (all sizes are considered in calcs), therefore 2 calcs will be performed, one for 24”
and the other for 12”
Calc for 12” pipe ... P=.328 x (2)(35,000)(0.9) / 12 = 1,722.66 or 1,723 psi is rating for limiting factor for 12”
pipe
Calc for 24” pipe ... P=.328 x (2)(35,000)(0.9) / 24 = 861.33 or 861 psi is rating for limiting factor for 24” pipe
Notice how pipe diameter affects pressure! Neither pipe size is near our 400 psi limiting factor
5.Check FBE internal coating spec (APCS 101) indicates pressure rating of 5,000 psi per SAES-H-002, not a
factor!
ACTION: Review Complete. Return test package to Engineering. Test pressure and arrangement are
unacceptable: 1. Test pressure of 450 psig is unacceptable as Ductile Iron Valves are rated for 400
psig.
2. Use of a closed ductile iron valve at test limits is unacceptable.
Recommendation: Reduce Test pressure to 400 psig. Test valves in open position with blind at test limit.
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SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008) Rev 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
Attachment 3 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
OVER PRESSURIZATION ALERT FOR LATERALS
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SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008) Rev 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)
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SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008) Rev 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 15-Dec-09 MECH-
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