SAIC-A-2001 Rev 6 Review Procedure - Pressure Testing (All Applications)

SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12
SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 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.
Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)
A
Sch Q,
Procedure is project specific, identifiable by Budget Item (BI) or Job
A1
Number, Contract Number & Project title & traceable to Quality Plan.
Para 3.1, 3.2
A) An approval section exists to document adequacy prior to use.

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

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

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

• Reference "Approved" Pressure Test Procedure
• Pressure Test Diagram* which shall include the limits of piping (including
test manifold arrangement) & equipment included in each pressure test,
high points & low points (vent, drain), locations of pressure gauges, test
pressures, test temperature, test fluid, line flushing reqmts & safety
SAEP-1160,
precautions (*Use a test symbol legend)
Section 8
• Relief valve capacity, testing and installation
See
• Pressure gages and recorders calibration records
Note 1 &
• SA Safety Instruction Sheet (critical piping), Pressure Test Report
B1
• Copies of P&ID & ISOs of the piping system to be pressure tested
SAIC-A-2003
• 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 GI-2.102
B2 • Test medium (water, treated water, lube oil, etc) and cleanliness
• Test pressure duration and limitations Para 5.1.2.5
• Special support requirements
• Test sequence (Controlled/staged pressure rise, 10-minute holds)
• Detailed Inspection & Test Crew responsibilities during testing
• Safeguards (Personnel clearance, Barricades, signs, permits)
• Staged and safe filling, venting and disposal practices
• Additional personnel & Equipment (radio, signals) used for tests
• Safety Instruction Sheets (Completion & Review Responsibility)
Procedure Equipment section details requirements as listed:

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

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

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

to start-up date with minimal time between introducing test water &
commissioning the equipment. Hydrostatic tests and lay-up procedure
shall be designed to protect corrosion-susceptible matls. SAES-A-007,
B5
Section 4.3.1, 4.4
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 Valve Section 4
B6 Field Testing is included in procedure (see API 598), add: See
Valve Shell also
Test, High-Pressure Closure Test, Low-pressure Closure Test & Backseat Attachment 2
Test (SAES-L-108, Section 4.7.6)
Procedure clearly states differences between test types
C Pipeline Pressure Testing Applications (Include in procedure if applicable per scope)
Pipeline Strength Tests for New Pipelines are detailed in procedure

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

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

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

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

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

Define Test
See Attachment 1. This shall cover all tests for On-Plot activities
Workscope
and, when reviewed with the Pressure Testing Specification, shall
&
D1 provide adequate instruction for Test Package Development & On-Plot
Specifications
pressure testing & other related testing activities including all Utilities
Sch Q,
(sewer, water), Firewater & Plumbing systems.
Att IV, Table 2.1
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 SAES-L-150,
D2
applicable SA requirements and ASME B31.3 or ASME B31.1 except as Section 5.3
noted. (Detail Exceptions in procedure)
Procedure details: Valve Pressure Test Applications, Test Facility, &

considerations before, during, and after testing:
A) Applications include Field hydrotesting per SAIC-L-2042 that
follow SAES-L-108, API 598, & ASME B16.34 requirements. Valves
require body & seat closure tests per SAES-L-108, Sect. 4.
SAES-L-150,
B) Valve Testing Facility meets SAIC-L-
Section 5.11
2031 (See Sections D & J). C) In-
D3 &
line testing of valves (body test, seat test restrictions & calcs)
SAES-L-108,
D) Post Test draining, cleaning, inspection and preservation
Section 4.7
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

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

SAES-L-150,
D6 (Check 100% joints)
Section 7.5.2
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
Page 4 of 23

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

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

A) Tie-in butt welds (to new or existing
pipe) are strength tested
SAES-L-150,
D8 B) Strength Test Pressure is based on minimum Code requirements if
Section 5
the tie-in is to an existing system.
C) If a strength test is deemed impractical, it can be substituted with a
request of NDT in lieu of pressure testing as processed.
Instrument impulse lines are hydrotested only as follows:
A) Liquid test is performed when the test pressure is greater than 1000
psig. Air or nitrogen use is allowed up to 1000 psig.
B) Between root isolation valve & instrument isolation using treated water
(or approved fluid) at 1.25 times system design pressure.
SAES-L-150,
D9 C) The test
Para 5.12
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
SAES-L-150,
D10 Heat Treatment (PWHT) is specified for that line.
Section 5.8
Note: Seal welded threaded connections, non-pressure containing welds
to attachments (wear pads, etc) are exempt from retesting unless the line
is specified for PWHT.
Procedure details retesting reqmts & responsibilities, and the
Database has capability for tracking such repairs.
Open-ended Piping (drains, vents & piping downstream of PZVs)

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

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

in procedure as follows:
A) Test entire hot or cold water supply system (test & prove
tight) under a water pressure of 1034 kPa (150 psig) for 4 hrs minimum.
Note 1: Test all piping within building from building
isolation valve. Note 2: Water
distribution piping network (utility piping from tankage) to building isolation
valve & connected fire hydrants are tested at 150 psig or 50 psig above
maximum operating pressure, whichever is greater.
Newly constructed water supply systems are SAES-S-060,

D12 disinfected per GI-0151.006, SA Sanitary Code, Chapter SASC-S-01. Para. 103.5.3.3
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)
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
SAES-S-060,
nitrogen (Oxygen prohibited) at test pressure not less than 1-½ times
Para. 103.5.3.3,
maximum working pressure, but not less than 60 psi (413kPa) for a period
Para
of not less than thirty (30) minutes.
D13 1204.3.2,
C) A low pressure air test not exceeding 345 kPa (50 psig), & soap bubble
test shall be used to test sanitary drainage or plumbing system of any
Para.
building premises when there is reason to believe that it has become
103.5.5.1
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 GI-
0151.006,
Saudi Aramco Sanitary Code, Chapter SASC-S-01.
Page 6 of 23

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

070, SATIP-S-020) are detailed in procedure as follows:
A) Test entire hot or cold water
supply system (test & prove tight) under a water pressure of 1034 kPa
(150 psig) for 4 hrs minimum.
B) Test Gas Systems (welds & joints accessible) with air, CO2, or
SAES-S-060,
nitrogen (Oxygen prohibited) at test pressure not less than 1-½ times
Para. 103.5.3.3,
maximum working pressure, but not less than 60 psi (413kPa) for a period
Para
of not less than thirty (30) minutes.
D14 1204.3.2,
C) A low pressure air test not exceeding 345 kPa (50 psig), & soap bubble
test shall be used to test sanitary drainage or plumbing system of any
Para.
building premises when there is reason to believe that it has become
103.5.5.1
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 GI-
0151.006,
Saudi Aramco Sanitary Code, Chapter SASC-S-01.
E Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)
In New Plants, Low pressure steel piping in water, instrument air, plant air,
inert gas (Nitrogen, etc.) & steam systems operating at 150 psig or SAES-L-150,
E1
lower are Service Tested (except FW systems). Section 9.3
Vessel Trim & Sampling lines also receive a Service test.
Service Test After Minor Leak Repairs (in Existing Facilities) is

detailed as follows in the procedure (as applicable per scope):
A) When small diameter threaded piping (in all services/pressures) repairs
are made, thread engagement and seal welding meets SAES-L-110 and SAES-L-150,
E2
NDE requirements, followed by Service Test. Section 9.1
Seal weld repairs are not done on Sch. 40 galvanized

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

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

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

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

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

A) Water & Pneumatic flushing (SAES-L-350 App. A) See Att # 2
B) Pressurized Air Shock Blowing (PASB) per SAES-L-350 App. A
C) By a Pre-job agreed upon procedure accepted by Company (SA) PMT,
Proponent & Inspection representatives. SAES-L-350,
G1
Section 15
See Attachment # 2. Cleaning and flushing methods are
incorporated into the procedure & test packages. Valve cavity (low
point) draining, drying, cleaning & reinspection measures shall be
detailed where no low point drains exist.
The general flushing medium is plant/ process water or raw water. Fire
water may be used where process water is not available. Sea water is not
acceptable. Water for hydrostatic test with pH less than 6 and/or SRB SAES-A-007
G2
counts greater than 10² per ml is unacceptable. Treat test fluid to control Section 4
corrosion and bacteria when applicable.
Employ regular water analysis, maintain certs and records.
Test Procedure details Lay-up & treatment of Hydrostatic Test Water for
Carbon & Low Alloy Steel systems as follows:
A) Follow 14-day rule with oxygen scavenger & 90-day rule with biocide
use in pipelines, use batching scrapers & nitrogen slug to separate air
from contacting treated water SAES-A-007 Para
G3
B) Lay-up per 60-day rule (14 days on exchangers) 5.2
• Wet, Dry, Inert Gas & Ambient Methods are detailed in procedure
• Boiler Layup is per SAEP-1026, Other methods are CSD approved
Procedure can utilize SAES-A-007, Section 5 in entirety
Test Procedure details Lay-up & treatment of Hydrostatic Test Water for
Stainless (300, 400 series) systems as follows:
A) Chloride content of test water is tested/certified below 50 mg/L.
B) Treat test water with oxygen scavenger (4-day contact rule) SAES-A-007
G4
C Treat test water with biocide (14-day contact rule) and lay- Section 6
up
• Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods
Page 8 of 23

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

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

of piping (including test manifold) and equipment included in each
hydrostatic test, test pressures, test temperature, test fluid, line flushing
requirements, and safety precautions.
SAES-A-004,
H1 Note: Pressure Test diagrams can consist of the following:
Section 5.6
• Marked P&IDs & Isometric drawings that use test symbol legend
• Copies of Manifold sketches and manifold test certificates.
• Procedure can allow multiple circuit testing (show jumper hoses)
Test manifolds are certified & tested to 1.2 times maximum test pressure
but not less than discharge pressure of test pump.
SAES-A-004 Para
H2 Manifold Test Report (Sketch & Certificate) is required. The sketch
5.5.4
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 SAES-A-004,
H3
C) Block valve Para 8.3
isolation is severely restricted & supported by calcs.
Fabricated test implements are rated, marked & inspected
During the application of the test pressure, all in-line valves if not used as
test isolation valves are verified to be in an open position. SAES-A-004,
H4
Inspectors check valve lineup & position prior Para. 9.1.3
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
SAES-A-004,
314 psi)
Para 8.3 &
B) Valves do not leakby (Successfully passed a seat
H5
closure test) C) Both sides
Attachment 2
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.
Page 9 of 23

ITEM
No.
Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are

reviewed by Engineering & verified by Inspection as follows:
• Hoop stress in pipe (nominal wall less mill tolerance) of 90% of Specified
Minimum Yield Strength (SMYS) at test temperature.
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
SAES-L-150,
• Valve pressure rating (1.5xASME B16.34 value, round up 25)
H6 Section 7.1
• Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design
Attachment 2
• Internal FBE Coating pressure rating is known, listed & considered
Ensure limiting factors are listed (SIS Sheets/test reports)
Prevent overpressurization & damage! See Excel Sheet 3
Components in new piping systems that interfere with filling, venting,

draining or flushing are not installed until after line flushing & pressure
SAES-A-004 Para
H7 testing are complete. (orifice plates, flow nozzles, sight glasses, venturies,
8.1.4
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. SAES-A-004 Para
H8
F) Other sensitive 8.2
equipment designated by SA Inspector*
*Soft seated valves & control valves are installed AFTER lines have
been thoroughly flushed (SAES-A-004 Para 7.1.3)
List items in
procedure and on reinstatement checklist
Vent & Drain installations for testing purposes are as follows:

A) Vents are provided at all high points in the piping system.
SAES-L-150,
H9 B) Drains are provided at all low points in piping system excluding
Section 6
submarine and buried pipelines. (Dead legs are not installed)
This is a Pre-
Hydrotest checklist item verified by Inspection
Relief valves of adequate capacity are set to relieve at 5% above test

pressure. Relief valve(s) are tested, dated, and tagged within one week
prior to the hydrotest for new construction projects. SAES-A-004 Para
H10
Contractor maintains list of 5.5.1
relief valves and has a SA approved vendor or system to do weekly
calibrations. Inspectors witness relief valve calibrations
All joints (threaded, welded & flanged) are exposed for visual leak
SAES-L-150,
H11 detection during the strength test. External coating/priming of such joints
Section 7.3
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). SAES-L-150,
H12
Inspection time may exceed test times listed in SIS sheets & Hydrotest Para. 7.2
reports (30 minute is a minimum).
Inspectors shall complete inspection before tests are ended.
Page 10 of 23

ITEM
No.
Temporary supports & other support considerations for above ground
piping installations during hydrotest are as follows:
A) Where required to
prevent damage to system
SAES-L-150,
H13 B) As highlighted in the approved hydrotesting
Section 6
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
SAES-A-004 Para
H14 pressure drops. Test crews shall allow additional time (15 minutes
9.1.1
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
SAES-L-150,
H15 from Cleaning, Flushing, and Hydrostatic Tests".
Section 11
Test
water reuse is restricted to ensure cleanliness & quality
After the test pressure is reached and before commencement of

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

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

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

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

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

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

testing is addressed in the procedure as follows:
A) All temporary items
installed for testing purposes (manifolds, valves, blinds, spacers, gaskets,
supports, etc) are removed. B)
Components that interfered with system filling/venting/draining & Sensitive
Equipment (removed before testing) are reinstalled.
SAES-L-310,
I2 C) Items such as instrument air tubing, check valve discs that
Section 22
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
REMARKS:
Pressure Test Procedure (SAES-A-004 Definition): Information assembled to ensure all requirements listed in GI-0002.102 , all referenced
SA & Industrial standards are met. Per SAES-A-004 Definition, test packages are part of the Pressure Test Procedure. This checklist provides
Note a complete detailing of all Pressure Testing Applications/Requirements for SA Projects. See Attachment 1.
Hydrotest, Pneumatic and Soap Bubble Leak Test*, Service Test, & Valve Testing, can be
1 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 3. Hydrotest Data Mgmt & Tracking Database per
2 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)
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 package development.
3 Submit early on major projects as Pressure Testing is almost always Critical Path on Projects.
Note Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) & adoption of
Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality. This section is not
4 repeated in other "Review Procedure" type special process checklists, yet is intended for all.
Page 12 of 23

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

ITEM
No.
REFERENCE DOCUMENTS:
1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing (Project Specific)
2. SA General Instruction Manual GI-002.102 (28 October 2008) Pressure Testing Safely
3. SAEP-1160 (10 July 2011) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects
4. SAES-A-004 (30 Jan 2011) General Requirements for Pressure Testing
5. SAES-A-007 (24 July 2011) Hydrostatic Testing Fluids and Lay-Up Procedures
6. SAES-L-108 (11 Oct 2010) Selection of Valves
7. SAES-L-150 (25 April 2010) Pressure Testing of Plant Piping and Pipelines
8. SAES-L-310 (29 April 2007) Design of Plant Piping
9. SAES-L-350 (22 April 2009) Construction of Plant Piping
10. SAES-S-010 (21 November 2009) Sanitary Sewers
11. SAES-S-020 (13 March 2011) Industrial Drainage and Sewers
12. SAES-S-030 (16 March 2011) Storm Water Drainage Systems
13. SAES-S-040 (10 March 2012) Saudi Aramco Water Systems
14. SAES-S-050 (5 Feb 2006) 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
17. SAEP-311 (13 September 2009) Installation of Hot Tapped and Stopple Connections (Use Latest Edition for Safety)
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
Page 14 of 23
SAUDI ARAMCO ID/PID - REV 0- 18-May-05(Standards Cutoff -March 2012) Rev 6 31-Mar-12
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 30-Apr-13 MECH-
Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)
SYSTEM TEST PRESS TEST CONSIDERATIONS & NOTES
&
Process DURATION
As Calculated* Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test
30 mins (min) required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu of
Piping 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 psig,
30 mins (min) whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely cleaned*
Systems (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) Per
A) Process See Notes SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours. If
Piping 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 tested
30 mins pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & (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 joints are
(150 psig Soap Bubble Test checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver
max) 30 mins Service tests and final gasket installation.
(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 between
(SAIC-A- Test at 5-10 psig the gasket and the seal weld. It shall be examined for leaks using a soap solution.
2016)
Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the
Piping 30 mins (min) Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined and
Incl. Tie-Ins 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 welding
REQMTS 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 pressure
PIPING 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 Impulse As Calculated* Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
Lines 30 mins (min) pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or
process equipment to which it is connected. Test duration shall not be less than 30 minutes.
Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater than 1000
psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).
Page 15 of 23
Internally FBE As Calculated* For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not exceed
Coated Lines 30 mins (min) 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 (Piping) 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
Skid-Mounted EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
Piping (Vendor) per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct misalignment,
(exceptions noted) physical damage or any modifications in-situ, pressure test the 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 isolation
(Checklist
Item D4)
valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a unique ID
number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique ID & corresponding
test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg & Database (Piping System, Line
Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (internal visual exam by
qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions & follow-up preservation reqmts) & segregation control to
prevent "mixing valves". Controlled System for Valve Placement exists.
SPECIFIC TESTING REQUIREMENT SUMMARY (ALL SA APPLICATIONS PER SAES-L-150, Section 6)

6.1 Plant Piping - Pressure testing of On-Plot Plant Piping shall be per SAES-L-150. See Section D of this Checklist.
6.2 Cross-Country Pipelines - Pressure testing of cross country pipelines shall be per SAES-L-150. See Section C of this Checklist.
6.3 Pressure Vessels - Hydrostatic testing for new vessels (shop or field fab) shall be conducted as follows:
ASME Section VIII, D1 to SAMSS-004, Para 16.3.8.1. & ASME Section VIII, D2 to 32-SAMSS-004, Para 16.3.8.2
Hydrostatic testing for existing vessels shall be conducted per SAES-D-008, Paragraph 10.1.
Pneumatic test as approved by Insp Dept Mgr (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2)
6.4 Heat Transfer Equipment - Hydrostatic tests for existing equipment shall be per SAES-D-008.
For pneumatic testing, refer to same as above for Vessels (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2)
Boilers receiving Hydrostatic test (new, field fabricated boilers) shall be in accordance with 32-SAMSS-021.
Boiler pressure test After Repair or Alteration, refer to SAES-D-008 & National Board Insp Code, NB-23.
Boiler Hydrostatic test during T&Is shall be per test pressure as specified on boiler's safety instruction sheet.
Heater Tube (coil) Assy Hydrostatic test for new, field fabricated heater tube assembly shall be per 32-SAMSS-029.
Heat Exchanger Tube bundles removed from X-chgr (maintenance) get in-situ shell side test per SAES-D-108 prior to return to service
Fin Fan X-chgr is strength tested (as stamped) in-situ prior to final acceptance (new project), & whenever transported.
6.5 Tanks - For new, field fabricated tanks, & existing tanks, hydrostatic testing shall be per 32-SAMSS-006 for large, low pressure welded tanks;
or 32-SAMSS-005 for atmospheric steel tank, as applicable.
6.6 Fire Protection Systems - Pressure test new & existing fire protection systems (SAES-B-017, GI-1781.001).
6.7 Refrigerant Piping Systems - Refrigerant piping serving building air conditioning systems shall be tested according to the requirements of SAES-
K-001 and the Uniform Mechanical Code (UMC), Section 1520.
6.8 Potable Water Systems - Potable water piping inside buildings shall be tested per the reqmts of Uniform Plumbing Code (UPC). Exceptions to
UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS
Potable water piping outside of buildings shall be tested per the requirements of SAES-S-040 (SAES-S-070, Section 18).
6.9 Utility Piping Systems - Utility systems, including irrigation piping & water distribution mains, shall be tested per SAES-S-070, Sect 18
6.10 Industrial Drainage and Sewers - Industrial drainage and sewers shall be tested per SAES-S-020 (SAES-070, Section 18).
6.11 Sanitary Sewers - Sanitary sewer systems within buildings shall be tested per reqmts of the Uniform Plumbing Code (UPC). Exceptions to
UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS
Sanitary sewer lines outside of buildings shall be tested in accordance with SAES-S-070 Section 18.
6.12 Storm Water Drainage Systems - Test per SAES-S-030 (SAES-S-070, Section 18) Note: Only OWS portions are tested.
Page 16 of 23
6.13 Miscellaneous Building Services Piping - Steam & condensate piping outside the jurisdiction of ASME B31.3, heating & cooling water piping,
vacuum & compressed air system piping for building services shall be tested per ASME B31.9, Building Services Piping.
6.14 Gas Cylinders - Gas cylinders shall be tested per Saudi Aramco Bottled Gas Manual. (Application - New Labs, etc)
6.15 Valves - Valves shall be tested in accordance with SAES-L-108, Section 4.7
6.16 Non Metallic Piping - Such as RTR, Thermoplastic, PVC/UPVC & CPVC shall be tested per SAES-S-070, Section 18.
Page 17 of 23
Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
SAES-L-150 Pressure Testing Definitions
Hydrostatic Test: A pressure test conducted using water or other approved liquid as the test medium.
Leak Test: A pressure test to ensure tightness of flanged and threaded joints at the test pressure. It
is normally conducted before initial start-up & after T&Is. A leak test is different from tightness test below.
Pneumatic Test: A pressure test conducted using air or other approved gas as the test medium or in conjunction with
liquid.
Revalidation Test: A pressure test performed to prove the integrity of existing pipelines or plant piping.
Service Test: A pressure test performed to prove the integrity of pipelines or plant piping using the service fluid at the
maximum attainable operating pressure.
Strength Test: A pressure test at an internal pressure determined in accordance with this standard and the applicable
Code* to verify the integrity of the piping systems for service at the design pressure.
Tightness Test: Pressure test to ensure piping system tightness (i.e., no system leaks) at test pressure.
*Strength test (ASME B31.8 code 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 -1°C or less) or steam with a minimum exit velocity of 15 m/s. Repeat
flushing until cleanliness is verified by observing an absence of any solids impact on a polished metal target at exit.
Pressurized Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an
alternative method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems removing
trapped liquid in the piping, or to verify cleanliness of small bore pipe where video inspection is impossible or inadequate
due to pipe dimension or configuration. Air shocking pressure shall never exceed working pressure of the system and
shall never be more than 810 kPa (115 psi). Safety precaution shall be considered in consultation with Area Loss
Prevention Division when this method is used. Repeat PASB until cleanliness is verified by observing the absence of
any solids impact on a polished metal target (mirror) at the exit. Install double filters on air compressors & frequently
drain water accumulation to ensure air quality & prevent fouling of piping systems and instrumentation.
Water Flushing: Equipment sensitive to damage during water flushing shall be removed, blocked off or isolated. A list
shall be prepared and be part of the flushing procedure. Ball valves shall be flushed in fully open position. All piping
systems shall be flushed using high pressure [60.8 mPa (8.8 ksi) minimum] jet such as rotating hose or rotating nozzle.
Below 4", use High Velocity Water Flushing (HVWF). On systems where high pressure jet flushing cannot be used due
to complicated shapes and/or long runs use HVWF or slug flushing. Water velocity shall be a minimum of 3 m/s.
General flushing medium shall be plant/process/raw water. Fire water is used where process water is not available. Sea
water is not acceptable. When flushing stainless steel lines, chloride ion content shall be less than 50 mg/L. After
flushing, piping systems shall be completely drained, dried to a dew point below -1°C and protected against corrosion.
Valve Cavities (low points) without drains shall be addressed in the procedure.
Mechanical Scrapers: Can be used under the condition that damage to the pipe interior surface shall not occur.
Page 18 of 23
Valve Considerations: Valve Cavities (low points) without drains shall be addressed in the test procedure.
Whenever any valve without a low point drain is tested in-line, steps shall be taken to assure:
1) Complete draining of low points including the valve cavity after testing.
2) Complete removal of debris deposited during flushing and filling. Demonstrate effectiveness of
flushing to prevent debris accumulation in low points. Reinspection after cleaning and examination of seating surfaces &
performance of manufacturer recommended preservation or corrosion control measures is one acceptable method.
Contact CSD. 3) Corrosion Protection measures
shall be per SAES-A-007. Ambient lay-up of 400* Series (13Cr) trim valves, (Trim 1, 4, 6, 7, 8 & 8A) is prohibited
without CSD approved corrosion prevention measures.
TEST WITH ISOLATION AGAINST VALVE SEATS (CALCS) PER SAES-A-004, SECTION 7.3
Example 1: A typical Carbon Steel Class 150 # system (Proposed for hydrotest at 450 psi, limiting factor = flange)
1. A test proposes isolatation against a closed valve (gate, ball or plug type). Valve has passed a body & seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 150 # steel gate valve (Refer to ASME B16.34, Group 1.1 Materials tables & Section 7 Pressure Testing & API 598
Table 3 & Table 4) has working pressure design rating of 285 psi.
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (285 x 1.5 = 427.5 = 450 psi)
• Determine Valve Seat/Closure Test pressure. Design = 110% or 1.1 per API 598 Table 3 (285 x 1.1 = 313.5 psi).
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 1 minute (valves to 12” NPS)
Do not allow a 30 minute hydrotest at 450 psi against the valve seat (because overpressurization results).
Resolution: Remove valve from line for test, install a 150# blind flange & proceed with test at 450 psi Or, reduce test
pressure to 313 psi & list valve seat closure as ""limiting factor"" if valve cannot* be removed for test (*justification &
Company
Example #2 approval
(Spec is required)
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.
Page 19 of 23
Quick Calc Steps: 1. Do not accept a test in 150# system against a closed 150# valve (typical for all classes)
Do not accept the proposed test against a closed gate valve. Perform thorough review even after finding an error.
2. Determine Flange Pressure ratings as follows:
• Pipe flg limiting factor per ASME B16.5 (Table 1-A, Mat'l Group 1.1 = ASTM A 105) Press Temp Rating Table 2-1.1
• Working pressure rating for Class 150 systems @ temp of 100 F = 285 psig (multiply value by 1.5 per Section 8.3)
• 285 x 1.5 = 427.5, round up to next increment of 25 = 450 psig (acceptable, as our listed limiting factor is 450 psi)
3. Determine Valve Pressure ratings by checking ASME B16.34 OR API 598 Table 2 & 3
Note: Class 150 Ductile Iron = 400 psig per Table 2 (shell test) & 250 psig (high pressure seat
closure test)
ACTIONS: Do not accept 450 psig test pressure. Class 150 valves (ductile iron) are tested to 400 psig (250 at seat).
B) Request a test pressure reduction to 400 psig and test limit revision & proceed with 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.
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.
Recommendation: Reduce Test pressure to 400 psig. Test valves in open position with blind at test limit.
Page 20 of 23
Attachment 3 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
OVER PRESSURIZATION ALERT FOR LATERALS
1. 100% HOLD POINT ON LATERAL BRANCH CONNECTION WELDS FOR COMPANY VISUAL
EXAMINATION OF ROOT ID. MEANS OF VISUAL EXAM MUST BE PROVIDED (EXTENSION
MIRROR / REMOTE VIDEO). USE WINDOW TECHNIQUE FOR ROOT EXAM
2. LATERALS MUST RECEIVE NDE ON ANY EXISTING /
SUSPECT ROOT CONDITIONS TO PREVENT POSSIBILITY OF FAILURE DURING PRESSURE
TESTING. 3. FULL ENCIRCLEMENT SLEEVES MUST REINFORCE ALL
LATERALS. 4. LESSONS
LEARNED (HAWIYEH FATALITY) ... NEVER ALLOW LATERALS ON ANY SYSTEM ABOVE
CLASS 150# ... CALCS PER ASME B31.3 Appendix H apply. Do not allow overpressurization.
See acceptable detail below. Angle may vary.
Page 21 of 23
OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)
Page 22 of 23
Page 23 of 23

SAIC-A-2001 Rev 6 Review Procedure - Pressure Testing (All Applications)

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SAIC-A-2001 Rev 6 Review Procedure - Pressure Testing (All Applications)

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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

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

Special Process Procedure includes details of Data Mgmt & Tracking

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

Procedure lists Pressure Test Package contents as follows:

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

Procedure Equipment section details requirements as listed:

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

Procedures for both hydrotests and service tests address safety

Procedure states: Hydrostatic tests are scheduled as close as possible

Definitions of various types of pressure tests are listed:

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

Pipeline Strength Tests for New Pipelines are detailed in procedure

Pipeline Tightness Test is conducted at 95% strength test pressure

Revalidation Pressure Tests for Existing Pipelines are detailed in

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

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

Procedure has an On-Plot Piping Pressure Testing Matrix.

Procedure states: A hydrostatic strength test shall be applied to all

Procedure details: Valve Pressure Test Applications, Test Facility, &

Sampling piping systems are pressure tested as an integral part of the

Underground process plant piping is tested as follows:

A) Prior to any backfilling for 2 hours minimum

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

For jacketed piping, the internal line shall be hydrotested according to

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

RETESTING of Piping systems that have already successfully passed a

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

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

Newly constructed water supply systems are SAES-S-060,

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

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

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

Seal weld repairs are not done on Sch. 40 galvanized

Revalidation Tests in Existing Facilities ensure test pressures are the

F Pressure Testing of Hot Tap & Stopple Connection

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

Pressure Testing (Hot Tap Installation)

Pressure Testing (Stopple Installation)

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

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

Special Test preparation requirements are met as follows:

H Detailed Pressure Testing Procedure Requirements (Include applicable requirements)

Hydrotest (Pressure Test) Diagrams and procedures include the limits

• Procedure can allow multiple circuit testing (show jumper hoses)

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

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

Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are

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,