SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Field Hydrostatic Testing of Isolation Valves SAIC-L-2042 30-Apr-13 MECH-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
General Requirements (Issues to be Resolved Prior to Testing to Provide Clear Field Direction)
A Note: Efficiency & Clear Direction exists for Special Construction Processes Before Work
Begins.
Testing location shall be specified by proponent.
SAES-L-108
Field Testing Shops shall be approved by Project Inspection.
A1
*These special process
Para 4.7.1
reqmts are listed in Attachment 1.
Proponent Specifies Valve Testing extent. List is available.
Attachment 1. Line Class List & direction exists for
testing. All new valves designated
for isolation service (as specified by the Proponent) shall be subjected to
SAES-L-108
A2 a high pressure hydrostatic seat test prior to installation in the line.
Para 4.7.2 & 4
Buttweld and socketweld end valves in nominal pipe size (NPS) 2
inches and smaller are exempt from field testing requirements.
VALVE BEING TESTED IS REQUIRED TO HAVE THAT
TEST

A low pressure pneumatic seat test at 35 kPa (5 psig) shall be

substituted for the high pressure hydrostatic seat test for flare system
valves. The boundary of flare system shall be agreed upon.
SAES-L-108
Note: The 24-inch
A3
requirement is gone. Valves downstream of Equipment PZVs & those
Para 4.7.3
"emergency" (locked) valves should constitute the boundary of flare
system as decided by Proponent. VALVE BEING
TESTED IS REQUIRED TO HAVE THAT TEST
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.
SAES-L-108
A4 Procedure shall be
supported by manufacturer instruction or any recommended Valve Para 4.7.5
Preservation requirements.
See Attachment 2 for Special Care and Valve Precautions.

Test crews & Inspectors are trained to properly follow testing procedures
SAES-A-004,
to eliminate water after testing and apply preservation measures such as
A5
mfg approved lubricants & other Corrosion Control measures. Procedure
Section 4
shall detail specifics. Attachment 2.

Before employing the pressure testing manifold in the actual system SAES-A-004,
A6 pressure test, it shall be separately pressure tested to at least 1.2 times
the system test pressure. SAIC-A-2009 Safety Checklist. Section 5
Test water Quality meets the requirements of SAES-A-007.
Testing intervals (maximum weekly) are established for test
water. Test water quality shall have a sulfate reducing
bacteria (SRB) count of 10³ per ml or less as determined by RapidChek SAES-A-007,
A7 II Method. Note: Section 4
Water with higher bacteria count may be acceptable if treated with
biocide & retested and approved by Supv. CTU/ME&CCD/CSD
See Attachment 2 & SAIC-A-2007 Lay-
up Checklist.
General Instruction GI-0002.102 "Pressure Testing Safely" shall be SAES-A-004,
A8
followed during pressure testing. Para. 5.1

B
TEST PREPARATION
CRITICAL: INSPECTION (INTERNAL/EXTERNAL) PRECEDES VALVE TESTING (ATTACHMENT 1)
The relief valve of adequate capacity set to relieve at 5% above the
hydrotest pressure shall be installed. The relief valve(s) shall be tested, SAES-A-004,
B1
dated, and tagged within one week prior to the hydrotest for new Para. 5.5.1
construction projects. Relief Valve current logs exist (M&TE).

Page 1 of 6
 Pressure gauges and pressure recorders are calibrated before the tests.
SAES-A-004
B2 The calibration interval shall not exceed one (1) month. Stickers shall be
Para 8.1.5.2
applied indicating the latest calibration date.

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Field Hydrostatic Testing of Isolation Valves SAIC-L-2042 30-Apr-13 MECH-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

All gages have a range such that the test pressure is within 30 to 80% of SAES-A-004
B3
the full range. Inspectors know the test parameters. Para 8.1.5.3

A minimum of two pressure gages are available for the test system. SAES-A-004
B4
Their accuracy shall be within 5% of one another. Para 8.1.5.4
SATR-A-2014 Water Chemistry Report is available, currently tested in SAES-A-007
B5 accordance with procedure and acceptable (SRB Count, etc) for the
application. Note: Different water requirements apply! (Procedure)
Test Records shall be made for each test by entries on Pressure Test
Report Form 2642-ENG* and the applicable "Safety Instruction Sheet"
per SAES-A-005. *SATR-A-2001V is used. SAES-A-004
B6
Documents uniquely identify valves with Para 9.3
unique ID number. Acceptance markings identify the
valve (per procedure).
C SHELL TESTS (API 598 Tables) Note: Enter Test Results in SATR-A-2001V for each valve.
For shell tests, visually detectable leakage through the pressure
SAES-L-108,
C1 boundary walls and any fixed body joint is not permitted. Criteria!
Para. 4.7.5
(API 598 Para 3.9.1.1)
Shell Test Pressure (API 598 Table 2)

SAES-L-108,
Para. 4.7.5
C2
API 598 Table 2
Notes b-c

Other Test Pressures (API 598 Table 3)

SAES-L-108,
C3
Para. 4.7.5

For Class 800 valves, shell test pressure shall be 1½ times pressure
rating* at 100°F (38°C), round up to next higher increment of 25 psi. SAES-L-108,
C4 NOTE: Para. 4.7.5
Check Valve Stamp for pressure rating. For Carbon Steel Valves, API 598 Table 3
1,975 psi is the usual pressure rating. Caution!

Duration of Required Test Pressure (API 598 Table 4)

SAES-L-108,
C5
Para. 4.7.5

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Field Hydrostatic Testing of Isolation Valves SAIC-L-2042 30-Apr-13 MECH-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

D HIGH PRESSURE SEAT CLOSURE TESTS (API 598 Tables) Note: Test Times per Item C5 above
Maximum Allowable Leakage Rates for Closure Tests
SAES-L-108,
Para. 4.7.5 &
API
D1 598
Table 5

Notes A-F

A) For the liquid test, 1 milliliter is considered equivalent to 16 drops.

B) There shall be no leakage for the minimum specified test duration
(see Table 4). For liquid test, 0 drops means no visible leakage per
minimum specified test duration. For gas test, 0 bubbles means less than
SAES-L-108,
I bubble per minimum specified test duration.
Para. 4.7.5 &
C) Maximum permissible leakage rate shall be 0.18 cubic in.
API
(3 cubic centimeters) per minute per in. of
D2 598
nominal pipe size.
Table 5
D) Maximum permissible leakage rate shall be 1.5 standard cubic ft
(0.042 cubic meter) of gas per hour per in. of nominal pipe size.
Notes A-F
E) For valves greater than or equal to NPS 14, the maximum permissible
leakage rate shall be 2 drops per minute per in. NPS.
F) For valves greater than or equal to NPS 14, maximum permissible
leakage rate shall be 4 bubbles per minute per in. NPS.

Equipment & Technique for Pressure Testing of Valves is available

(same as used by Valve Manufacturer) in procedures as follows:
A) Measurement Hypo Syringes
(Extended tip to access low points) During exams, leakage is assessed
at rates/time in tables above. B) Pressure Testing
Bench or Table (Valves are kept off ground)
SAES-L-108,
D3 Procedure allows multiple shell tests of
Para. 4.7.5
valves bolted together in horizontal position to prevent trapping of air (for
efficiency). C) After Shell test passes, perform
Seat closure tests. (Efficiency) Avoid
trapping air in valve high points during seat testing due to improper valve
orientation, filling, & venting. Several techniques to reduce trapped air
exist. Choose a method that assures efficiency.
Method of water removal, corrosion control measures incl. layup &
preservation (per procedure) is effectively & consistently applied in SAES-L-108,
D4
accordance with all SA & Valve Mfg. requirements after testing. Para. 4.7.5

REMARKS:

NOTES: Rejected Valves are dispositioned (repaired & retested) per Attachment 1 Requirements. USE SATR-A-2001V.
ATTACHMENTS: Attachment 1 - Valve Testing Facility Approval, Start-Up & Other Quality Requirements Including Repairs
Attachment 2 - Valve Testing Special Considerations
REFERENCE DOCUMENTS:
1- SAES-L-108 (21 March 2010) Selection of Valves
2- SAES-A-004 (14 December 2009) General Requirements for Pressure Testing
3- API 598 Valve Inspection And Testing

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:

QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

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

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Field Hydrostatic Testing of Isolation Valves SAIC-L-2042 30-Apr-13 MECH-

Attachment 1 - Valve Testing Facility Approval & Start-Up Requirements

Valve Testing at new shops is approved by SA Proponent as a desirable location for any field testing prior to line
installation. On Projects, Field Testing locations shall be approved by Saudi Aramco, including Project Inspection.
Receiving Inspection is organized, follows an efficient procedures. Use SAIC-L-2040 Checklist & SATR-A-2001V.
Storage & Preservation is organized, follows efficient procedures. Use SAIC-L-2041 Checklist & SATR-A-2001V.
Valve Testing Set-up is adjacent to storage areas to minimize handling. Consider prevailing winds and fouling.
1. Proper segregation shall exist for CS, NACE & SS valve materials.
2. An adequate water supply (treated or demin water) exists & meets SAES-A-007 reqmts for testing and purity.
Refer to SAES-A-007 Lay-up Procedure & Checklist & all attachments relative to Valve Testing
3. Test Equipment is available as follows and does not promote fouling & contamination of alloy components:
A) Pressure Test manifold rated for work per SAES-A-004 reqmts. Perform check for Safety (SAIC-A-2009)
B) Pressure hoses rated for the work
C) Water tanks, mixing apparatus & filling hoses
4. Procedure for Field Testing of Valves is approved.
5. Personnel including QC dedicated to Valve receiving inspection & field testing have experience with valves and
have been approved. Furthermore, they shall have access to required reading and specific/acceptable experience.
Copies of applicable Code and checklists are available for Inspection Personnel performing Valve Testing.
6. List of valves to be tested is available before the start of work & meets SA standards and approved testing
procedure.
7. Records, QC form & unique ID numbers exist for every valve tested.
Valves are traceable to their unique test reports and a unique Identification Number. This is identified in line
installation and verified by Inspection
8. Preservation of mfg Identification tags (during coating) is strictly enforced. No Sandblasting damage to tags.
Tags are protected by suitable means (taping, etc). Ends are sealed during sandblasting operations carefully.
Valve Testing Extent (Requirements)
NOTE: A CLEAR AND AVAILABLE LINE LIST WITH CLEAR AND AVAILABLE DESCRIPTION FOR VALVE
TESTING (INCLUDES EXCEPTIONS TO VALVE TESTS) IS AVAILABLE BEFORE THE START OF WORK TO
PROVIDE CLEAR AND EFFICIENT DIRECTION & PREVENT TESTING OF VALVES THAT IS NOT REQUIRED.
PROPONENT SHALL SPECIFY THE PARAMETERS OF THIS LINE LIST & CONTRACTOR SHALL IDENTIFY
EACH WITH A UNIQUE ID NUMBER TRACEABLE THROUGH THE ENTIRE CONSTRUCTION PROCESS UNTIL
MCC. ALSO, THOSE FLARE SYSTEM VALVES SHALL BE IDENTIFIED EARLY IN THE PROCESS TO PREVENT
THEIR HYDROTESTING IN ACCORDANCE WITH SA STANDARDS.
Valve Repairs (Procedure, Approval by SA & Documentation)
1) Prior to pressure testing (as detailed in Valve Testing procedure & agreed upon by Company), Visual
internal/external valve inspection shall be completed on each valve by qualified Valve Testing Inspector.
Defective (visually unacceptable) valves are identified (Company informed in all cases) and documented
thoroughly in a Quality log for Rejected Valves (Unique ID Number & Traceability exists).
NO VALVE REPAIRS SHALL BE PERFORMED UNLESS & UNTIL SPECIFIC
NOTIFICATION & APPROVAL FROM SA IS REC'VD. (AS AGREED UPON)
COMPANY (INSPECTION) SHALL BE INFORMED IN A TIMELY MANNER AND
SHALL HAVE OPPORTUNITY TO WITNESS ANY & ALL REPAIRS.
ALL REPAIRS TO NEW VALVES (FOR WHATEVER REASONS) SHALL BE
THOROUGHLY DOCUMENTED BY CONTRACTOR QC & INSPECTED.
VALVE MANUFACTURER SHALL AUTHORIZE REPAIRS TO NEW VALVES.
ONLY APPROVED SHOPS (SA & VALVE MANUFACTURER APPROVED)
PERFORM AUTHORIZED REPAIRS. DOCUMENT ALL VALVE REPAIRS.
IF APPROVED & WITNESSED BY COMPANY, FIELD TESTING AFTER REPAIRS
MAY BE WAIVED AT SITE (IF REPAIR TESTED/SA ACCEPTED)

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Field Hydrostatic Testing of Isolation Valves SAIC-L-2042 30-Apr-13 MECH-

Attachment 2 - Valve Testing Special Considerations
SPECIAL CARE FOR 13Cr (400 Series) Trim SS VALVES
Trim 8 is the most common type of valve used in Saudi Aramco Plants.
This requirement was specifically cited for Pipelines, as severe corrosion occurs with extended improper
Lay-up. CSD has stated that this also applies for Plant Piping. This is common sense & must be addressed
in Plant Piping Pressure Testing & Valve Field Testing & Subsequent Lay-up Actions as follows:
1. Valves coming from the manufacturer are pressure tested and "lay-up" is "OTHER" or Special:
a) Valve manufacturers takes great care to stroke valves and allow water "time" to descend from bonnets
b) Water is then blown out using high pressure air until water is removed. Moisture is still present.
c) Valve Manufacturer "APPROVED CORROSION-RESISTANT LUBRICANTS" are then professionally
applied by trained valve testing technicians who distribute lubricant in effective methods to prevent rust.
d) Valves are then stroked and lubricants are spread evenly over sealing surfaces to prevent corrosion.
e) Valves are then coated and sealed/covered shipped to Saudi Aramco for installation in our facilities.
f) Valve handling during shipping and Other* Concerns (age in storage, corrosion consideration, damage)
requires the Safeguard of "FIELD TESTING OF CRITICAL ISOLATION VALVES" per SAES-L-108.
g) Valves are then again opened & inspected for warranty coverage for shipping damage/other concerns.
h) Valves are field tested (body test, high pressure seat test, other tests as required by SAES-L-108).
CORROSION CONTROL CONSIDERATIONS ARE NOW THE RESPONSIBILITY OF THE CONTRACTOR!!!
At a minimum, Contractor Procedure SHALL:
1. Apply the same lay-up and care after Valve Testing that was applied by the Valve Manufacturer.
This includes careful drying and application of lubricants and corrosion control measures applicable.
2. Perform routine "PRESERVATION CHECKS" when valves (13 Cr trim or 400 series SS) are stored
longer then 30 days after field testing to assure effective corrosion control measures.
3. IF OPTION B IS SELECTED AND THE VALVE IS THEN TESTED IN-LINE, CONTRACTOR SHALL NOT
ALLOW AMBIENT LAY-UP OF VALVES (13 Cr Trim or 400 Series SS). WHERE VALVES HAVE NO DRAIN,
COMPLETE REMOVAL OF WATER FROM VALVE CAVITIES "SHALL BE DEMONSTRATED" to comply with
SAES-A-007, Para. 5.2.5.1 a). Valves may be removed after test and treated similarly to Valve Testing.
NOTICE: PROCEDURE SHALL DETAIL THE METHOD USED TO ASSURE COMPLETE REMOVAL OF WATER
FROM VALVE CAVITIES, CORROSION CONTROL MEASURES & PRESERVATION CHECKS DURING LAY-UP.
FOLLOW UP VALVE CHECKS FOR CORROSION DEMONSTRATE EFFECTIVE PRESERVATION (LAY-UP).
SAES-L-105 Valve Trim Table (Page 2/2)

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