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SAUDI ARAMCO ID/PIEU-31-Dec-2020 - REV.2020.12.00 (Standards Cutoff - Dec 31,2020) Rev 62 31-Dec-20
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 31-Jan-21 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?
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,
Other sections for special process control procedures (per Sch Q)
A4
detail references, responsibilities, definitions & procedure reqmts.
Para 3.1, 3.2
General Requirements
Note 1: Use SAIC-A-2003 for specific Test package responsibilities & instructions
B
Note 2: Use SAIC-A-2009 for specific Testing Equipment requirements including Safety
Inspections
On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
D
SAES-L-150,
Lube and seal oil piping is strength tested in its own fluid at the
D5 Section 7
greater of 1.5 times design pressure or 100 psig (for 30 minutes).
Para 7.5.1
E Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)
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).
Use
F2 Hot Tap/Stopple & Reinforcement Calculation Request-Form 7627
SAIC-L-2091
G Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)
Test manifolds are certified & tested to 1.2 times maximum test
pressure but not less than discharge pressure of test pump.
Manifold Test Report (Sketch & Certificate) is SAES-A-004
H2
required. The sketch lists detailed information/ratings of all Para 5.7.4
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
SAES-A-004,
H3 isolate test sections
Para 5.13
C) Block valve isolation is severely restricted &
supported by calcs. Fabricated
test implements are rated, marked & inspected
During the application of the test pressure, all in-line valves if not
used as test isolation valves are verified to be in an open position. SAES-A-004,
H4
Inspectors check valve Para. 6.1
lineup & position prior to testing.
Closed block valves (gate, globe, plug, and ball) may be used to
isolate equipment or piping sections (provided the valves are not
passing, otherwise the spectacle plate/blind shall be installed in the
closed position). 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 tested, due to possible leak through the SAES-A-004,
H5 valves. Section 5.13
When a block valve is used for isolating test sections, the differential
pressure across the valve seat shall not exceed the seat test
pressure during pressure testing and shall not exceed the rated seat
pressure during tightness test. Both sides of this valve shall be
protected by relief valves during the test.
All joints (threaded, welded & flanged) are exposed for visual leak
SAES-L-150,
H11 detection during the strength test. External coating/priming of such
Section 7.3
joints is not allowed unless approved by ID Manager & Proponent
Test duration and hold times consider full inspection access via
scaffolding & manlifts as necessary to allow visual inspection of
100% of all joints including weep holes, 6mm drain holes in dummy
SAES-L-150,
H12 legs (required). Inspection time may exceed test times listed in SIS
Para. 7.2
sheets & Hydrotest reports (30 minute is a minimum).
Inspectors shall complete inspection before
tests are ended.
Disposal sites for the test fluid shall be reviewed and approved prior
to the hydrostatic test in accordance with SAEP-327 "Disposal of
Wastewater from Cleaning, Flushing, and Hydrostatic Tests". SAES-L-150,
H15
Section 10.3
Test water reuse is restricted to ensure
cleanliness & quality
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.
Note This checklist provides 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 one (1) procedure (Pressure Testing). Small projects (less than 500 welds) do not
1 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
Note Controls) 2.
Sample Hydrotest Package Per SAIC-2003 3.
Hydrotest Data Mgmt & Tracking Database per SAEP-1160
2 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. Submit early on major projects as Pressure Testing is almost always Critical Path on Projects.
3
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 repeated in other "Review Procedure" type special process checklists, yet is intended for all.
4
ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA Projects
Attachment 2 - Pressure Testing Inspection Guide
REFERENCE DOCUMENTS:
1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing (Project Specific)
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of
new constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below.
Lube & Seal Oil See Notes *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100
30 mins (min) psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be
Systems completely cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints
Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged
and threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the
joints (check low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.
Underground As Calculated A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B)
A) Process See Notes Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.
Piping If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd.
B) Utility Piping
Flare Lines See Notes Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength
30 tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & mins (min)
above)
Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less
than 24 inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5
psig in lieu of a high pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc
when requested by Company. Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.
Vacuum Piping See Notes Tested to 1.5 times the differential external pressure, but not less than 15 psig.
30
mins (min)
Air & Inert Gas SERVICE TEST & Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded
(150 psig Soap Bubble Test joints are checked for engagement (two full visible thread rule). Coordinate with Compressor
max) 30 and Receiver Service tests and final gasket installation.
mins (min)
LP Steam SERVICE TEST Coordinate with system Service tests and construction completion.
(60 psig max) 30 mins (min)
Weld-Plus-Ends Soap Bubble Leak Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus
(SAIC- Test at 5-10 psig between the gasket and the seal weld. It shall be examined for leaks using a soap solution.
A-2016)
Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required
Piping 30 mins (min) by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be
Incl. Tie-Ins determined and taken into consideration when calculating the test pressure. In case of flanged
tie-in connections, a flange tester is utilized to conduct hydrostatic testing of flange butt weld.
RETESTING See Notes Systems that already passed a successful pressure test require RETEST IF subjected to new
REQMTS welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE
RETEST UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).
REPAIR See Notes Every existing plant piping & pipeline, after repairs or alterations have been made that affect the
EXISTING integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test
PIPING pressure shall be in accordance with the requirements of the applicable code.
Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc
Open-Ended EXEMPT, Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
Piping VISUAL EXAMatmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed,
etc
Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined.
Instrument As Calculated* Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
Impulse Lines 30 mins (min) pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system
or process equipment to which it is connected. Test duration shall not be less than 30 minutes.
Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater
than 1000 psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.
Sampling Lines See Note Test as an integral part with the piping or equipment to which it is connected.
Vessel & Tank See Note Test separately (separate package) as required. Exemptions include sight glasses
Trim & other instruments. Strength or Service test associated piping based on service
(Piping)
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test
Skid-Mounted EXEMPT IF TESTED BY 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
Piping (Vendor) VENDOR per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct
misalignment, physical damage or any modifications in-situ, pressure test the
(exceptions noted) affected spools.
FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042)
Test Location See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Field Testing of See Note All new valves designated for isolation service (as specified by the Proponent) shall
be subjected to high pressure hydrostatic seat test prior to installation in line.
New Valves
Exception See Note Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!
Exemption See Note Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt
Procedure See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be
equal to those that the valves were originally purchased to. All resilient (soft)
(Checklist Item D4)
seated isolation valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a
unique ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a
unique ID & corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg
& Database (Piping System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing
incl Receipt Inspection (internal visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions
& follow-up preservation reqmts) & segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.
6.12 Storm Water Drainage Systems - Test per SAES-S-030 (SAES-S-070, Section 18) Note: Only OWS portions are tested.
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
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.
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19
OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)
SAUDI ARAMCO ID/PIEU-31-July-2019 - REV.2019.07.00 (Standards Cutoff - July 31,2019) Rev.2019.07.00 31-Jul-19