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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Verify Test Equipment (Safety Assessment) SAIC-A-2009 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.
Note TEST EQUIPMENT SAFETY ASSESSMENT (Notes 1-7) ... Perform along with SAIC-A-2011.

On New & Existing Projects, Test Equipment shall be thoroughly inspected & certified for safety (new & existing test equipment). Responsible
1
persons shall be Project QA/QC Mgr and designated Hydrotest Engineer and Mechanical Inspector(s).

Regular inspection/maintenance of appropriate test equipment is mandatory to assure Safety on SA Projects. Use of existing equipment is
2 permitted if equipment does not exhibit signs of deterioration & is regularly inspected (Per Note 7) and meets GI-2.102 Safety Requirements.
Recommended is use of corrosion inhibitor when equipment is not in use for long periods.

Check component corrosion & wear (especially small fittings, nipples, etc) on existing equipment, especially test pumps. A thorough visual
exam includes accessible internal components (use mirror & sunlight technique), a UT exam or hammer test (never hammer pressurized
3 piping). Perform this exam in presence of COMPANY Inspection for new projects just prior to testing existing manifolds. Fittings and
components found with heavy corrosion or thinning (verified wall loss) shall be replaced. Heavily Corroded fittings give a dull sound when
hammer tested (new steel = ringing sound). Perform UT on suspect fittings or replace ASAP.

Existing Manifolds proposed for use on projects without detailed code construction documents (Engineering calcs & Inspection) must be
certified for fitness and safety. Existing test reports alone are not acceptable support documents. Code construction detail, calculations (SIS
sheet), appropriate Inspection and NDE are necessary for Safety. Unknown piping schedules can be determined by using a UT Thickness
4
meter. Ratings for most fittings are stamped/visible. Weld quality is verified by VT or RT. Test manifolds frequently used, older than two years
and stored in ambient conditions are highly susceptible to accelerated internal corrosion and thinning of components due to corrosive nature of
test waters used in many locations. Detail Manifold Arrangement Dwgs.

Fabricated test components (blinds, spools, welded couplings, etc) are of proper code construction, receive inspection and are
properly identification/marked for their pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never allow uninspected non-
5
code test component use. Components found unfit for testing (non-code, under thickness or schedule & without calculations, deteriorated,
damaged, corroded) are reported and removed ASAP from Company Projects.

Manifold design shall include limiting factor for all components (isolation valves, piping, fittings, tubing, etc). that are calculated (by design) to
provide a PRESSURE RATING of 20% above the maximum expected system for test. Isolation valves shall be one Class higher than
systems tested. Example: Project's greatest System Class = Class 900, CS (Normal), pressure rating 2,220 psi (test pressure = 3,350 psi). A
manifold is needed to meet COMPANY safety requirements. Step 1: Maximum test pressure for Class 900 systems = 2,220 x 1.5 = 3,330,
6 round up to nearest increment of 25 = 3,350 psi. Step 2: Manifold minimum design pressure (manifold test pressure) SHALL = 3,350 x 1.2 =
4,020 psi. Step 3: Manifold isolation valve must be Class 1500 minimum (one class above Class 900) See ASME B16.34 Tables & Para 7.2 = a
110% pressurization rule for valve seat closure tests. Step 5: Components (piping, fitting, tubing, etc) are rated for 4,020 psi minimum and
have engineering calcs to support their use. Manifolds without construction details (arrangement drawings) are not accepted until CERTIFIED &
RATED for Safety.

Perform safety checks for Notes 1-6 at least yearly* & before the start-up of pressure testing on projects. *Observation: The Diving
Industry requires appropriate test equipment maintenance inspections on an annual basis. Scuba Tanks are pressurized frequently to 3,200 psi,
often on a daily basis. Annual inspections use remote visual means (fiberscope). Corroded Tanks are replaced before they fail. Pressure
7
Testing equipment sees similar and even greater pressures and service use. Safety of Test Crews, Inspectors & personnel on Projects deserve
similar consideration. Keep Test equipment in good condition (Coated as needed, clean, legibly rated for pressure, legibly marked "as
inspected, and regularly inspected).

Page 1 of 5
A Test Manifold & Appurtanances (Piping, Fittings, Hoses) - Verify Test Package Content before Testing

Manifold Arrangement Drawing(s) attests to equipment safety:

A) Fabrication is per code construction with component
details listed such (Class, size, schedule piping, type isolation valve, etc).
B) Maximum Safe Test Pressure
Rating based on limiting factor. C) Each test G.I.-2.102,
A1
manifold is identified with a unique number (certificate) Para. 5.1.5.5
D) Shows actual arrangement including hose configuration used
Note 1: Manifold permanent marking
(unique ID #, pressure rating) is legible, traceable & certified for safety
(Support documenation).

Manifold Design Pressure Rating (Compare SIS for manifold & the G.I.-2.102,
A2 system to be tested) exceeds system test pressure by 20%. Para. 5.1.5.5
Safety Note 6

5.5.4.1 The test manifold shall be designed and constructed to meet

the minimum system requirements and approved by the Engineering SAES-A-004
A3
Division head in operating facilities or responsible Project Para. 5.5.4.1
Inspection Division head in new construction.

SAES-A-004
A4 Test manifolds shall have 100% NDT of all welds.
Para. 5.5.4.2

Page 2 of 5
SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Verify Test Equipment (Safety Assessment) SAIC-A-2009 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

B Verification of Actual Test Equipment Set-up (Manifold Arrangement)

Test Set-up* matches actual Test Manifold Arrangement.

Note 1: *Pressure Test Diagram with an
appropriate Legend for symbols, Test Manifold Arrangement (& pressure G.I.-2.102,
hoses/piping) show all high points (vents), low points (drains), gage Para. 5.1.2,
B1
locations & provide documentation that attests to the actual test as SAEP-1160,
performed. In event of testing accident, Loss Prevention Dept must be Section 8
able to use diagrams & sketches to recreate actual test set-up/conditions.

Blow down valve is adequately rated at higher class than system under
G.I.-2.102,
B2 test, and is installed to depressurize the system safely and is easily
Para. 5.1.5.3
accessible to operator. (Safety Note 6, Isolation valve)

Blind flanges, paddle blinds or spectacle blinds shall be used to isolate the
test sections. They shall be the same class rating of the system or may be SAES-A-004
B3
fabricated from verifiable identification of base material and approval of Para. 8.3
calculations by the Supervisor, CSD Piping Unit.

If closed block valves are used in lieu of blinds, provisions shall be made
to ensure no overpressure can occur in the system that is not being SAES-A-004
B4
tested, due to possible leak through the valves Both sides of this valve Para. 8.3
shall be protected by relief valves during the test.

If block valves are used for blocking or isolating hydrotest sections, the
differential pressure across the valve seat shall not exceed the seat test SAES-L-150
B5
pressure during the strength test and shall not exceed the rated seat Para. 5.10
pressure during the tightness test.

C Test Relief Valve(s)

Relief valve is located in the system under test and near the test pump
G.I.-2.102,
C1 with Isolation valves on the inlet and outlet of the relief valve sealed open
Para. 5.1.5
during the test. (SAEP-1160, Bullet Item # 3)

Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available) are
set to relieve at 5%* above the hydrotest pressure. SAES-A-004 Para
C2
*Note: Test pressures less than 85% of SMYS can have relief valves 5.5.1
set at 10% above test pressure. Verify SIS sheets/calcs.

Tested relief valve(s) with a tag stamped with the word "TEST", the set G.I.2.102
pressure, and date is checked. Stamp date validity is a period of one week Para 5.1.5.1
C3
for project pressure tests. Stickers are legible & valid. SAES-A-004 Para
A roster is kept for Pressure Relief Valves (M&TE) on projects. 5.5.1

In addition to the pressure relieving device, a bleed valve shall be

provided to protect the piping and equipment from overpressure. The SAES-A-004
C4
bleed valve shall be readily accessible in case immediate Para 5.5.2
depressurization is required.

Page 3 of 5
SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Verify Test Equipment (Safety Assessment) SAIC-A-2009 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 Pressure Gages and Recorders

A minimum of two pressure gages are required for test systems, with
accuracy within 5% of one another.
Note 1: When large systems are tested, Inspection personnel will
determine the need for additional gages.
SAES-A-004 Para
D1 Note 2: Elevation changes (hydrostatic head considerations) &
8.1.5.4
hot weather create pressure testing problems with frequent popping of
relief valves. For this reason, gage accuracy within 2% is best.
Note 3: Careful handling of delicate instruments as test gages is
practiced by test crews. No gage damage or mishandling is found.

Pressure gages and pressure recorders are calibrated within (1) month SAES-A-004 Para
D2
prior to test. Stickers applied indicate latest calibration date. 8.1.5.2

G.I.-2.102,
Avoid the following typical examples of poor practices:
Sec.4 &
D3 Testing equipment with the test gauge located at the bottom of the
SAES-A-004,
equipment reading the test pressure,including the head of test water
Para 5.3

All gauges have a range such that the test pressure is within 30% to 80% SAES-A-004 Para
D4
of the full range. 8.1.5.3

E Temperature Gages and Recorders (When Required, ie: 24-hr Recorded Tests)

Pressure and temperature recording gauges shall be used for all buried SAES-A-004 Para
E1
piping systems on plot and per SAES-L-150 for pipelines. 8.1.5.6

Bubble Leak Test (associated with Pneumatic strength/service test)

surface metal temperatures shall be recorded and compatible with test
methods (including test solution used to detect leaks). SAES-A-004 Para
E2
Note: ASME V, Art 10, Man. App. 1, Table 1-1021 requires surface 5.6.3
metal temp measurements during testing (detailed in procedure). Record
maximum (direct sun) & minimum test temperatures.

Thermocouples are installed to obtain accurate pipe metal temperature

measurements and to determine the acceptance of the pressure test SAES-L-150,
E3
where pressure variations due to test water temperature changes occur, Para. 11.3
such as in cross-country pipelines.

REMARKS:

REFERENCE DOCUMENTS:
1. SAES-A-004, General Requirements for Pressure Testing, (30-Jan-2011)
2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely, (28 October 2008)
3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (25-April-2010)
4. Pro Forma Contract Schedule Q (Project Specific)
5. SAEP-1160, Tracking and Reporting of Welding,NDT and Pressure Testing for Capital Projects (10-July-2011)

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:

Page 4 of 5
SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Verify Test Equipment (Safety Assessment) SAIC-A-2009 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No. Work is Complete and Ready for Inspection:
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: Name, Organization, T&I Witnessed QC Record Reviewed Work Verified
Name, Sign and Date:
Initials and Date:

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

Page 5 of 5