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KACWC – PROJECT 8483 – QA/QC DEPARTMENT Date February 9th, 2011

PROJECT: 8483
KING ABDULAZIZ CENTER FOR WORLD CULTURE

METHOD STATEMENT:
PNEUMATIC TEST

00 Initial 09.02.11 R.S W.K P.R M.S H.A

Rev Comments Date Prepared Reviewed Technical Reviewed Reviewed Approved

QC QC Reviewed QC LP SPM
SV SME MGR MGR

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CONTENTS:

1.0 PURPOSE

2.0 SCOPE

3.0 ABREVIATIONS

4.0 RESPONSIBILITIES

5.0 REFERENCES

6.0 TOOLS & EQUIPMENTS

7.0 PROCEDURES

8.0 LOSS PREVENTION

9.0 ATTACHMENTS

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1. PURPOSE

The purpose of this document is to describe the procedure to be followed for pipe
pneumatic test. This procedure details instructions to be followed and the
documentation to be employed in order to ensure that safe pipe pneumatic test is
executed in accordance with the specification and standards.

2. SCOPE

The scope of this method statement is to define all activities and requirements
necessary for pipe pneumatic test. The test will cover the following piping
services:

 Laboratory & Vivaria gas piping ( CO2 and

N2)Vacuum Piping
 Compressed Air Piping
 Reinforcing Pads

3. ABREVIATIONS

M.S Method Statement

ITP Inspection & Test Plan
RFI Request for Inspection
S.O.L Saudi Oger Limited
S.A Saudi Aramco
QC Quality Control
SAPID Saudi Aramco Project Inspection Department
SAPMT Saudi Aramco Project Management Team
SAIC Saudi Aramco Inspection Checklist
SATR Saudi Aramco Test Report
UG Underground
AG Above Ground
PRV Pressure Relief Valve

4. RESPONSIBILITIES

4.1 QC Inspector – Prepare the Method Statement

4.2 QC Supervisor – Review & Update
4.3 QC Manager, HSE Manager
4.4 Senior Mechanical Engineer – Technical Review
4.5 Site Project Manager – Approve
4.6 Construction Managers / Site Engineers / Site Foremen – Implement

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5. REFERENCES

The following is the list of references which are applicable to the scope of this
Method Statement.

5.1 International Codes

ASME B31.3 Process Piping
UPC Uniform Plumbing Code

5.2 Saudi Aramco Standards

SAES – A – 004 General Requirements for Pressure Testing
SAES – B – 017 Fire Water Systems Design
SAES – D – 008 Repairs, Alterations & Re-rating of Pressurized
Equipment
SAES – S – 060 Saudi Aramco Plumbing Code
SAES – L – 056 Pressure Testing of Pipelines & Plant Piping
SAES – J – 901 Instrument Air supply System
G.I.2.202 Pressure testing safely
SATIP–A–004–01 SATIP for Pneumatic Pressure Testing
SAIC – A – 2001 Review of Pressure Test Process
SAIC – A – 2003 Review Test Pack Preparation
SAIC – A – 2004 Verification of Pneumatic testing Media
SAIC – A – 2020 Filling & Pressurization for Pneumatic Testing
SAIC – A – 2021 Visual Inspection of Pneumatic Test
SAIC – A – 2010 Pre-Test Punch Listing On-Plot Piping
SAIC – A – 2016 Visual Inspection of Pneumatic Test for Reinforcing
SATIP – A–2009 Verify Test Equipment (Safety Assessment)

6. TOOLS / EQUIPMENTS

Conventional tools and/or equipments will be used as necessitated by work

procedures.

7. PROCEDURES

7.1 Introduction: This method statement is applicable to Pneumatic pressure

test of pipes.

7.2 PNEUMATIC PRESSURE TEST PROCEDURE:

7.2.1 PREPARATIONS:-

7.2.1.1 Testing packages shall be formed of the following documents:

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7.2.1.1.1 Flow chart of Test Package denoting responsible agencies

for tracking and confirmation of the various inspection
requirements (SAIC-A-2003)
7.2.1.1.2 Calibration certificates for pressure gauges
7.2.1.1.3 Pressure relief valve data sheet calibration certificates
7.2.1.1.4 Pressure test diagram showing the layout, routing and
limits of pipes to be tested
7.2.1.1.5 Isometric drawing of tested pipe network
7.2.1.1.6 Pre–Test punch list checklist: SAIC-A-2010
7.2.1.1.7 Final Punch list: SAIC-L-2022

7.2.2 The testing package documents shall be submitted to S. Aramco for

review 1day prior to each time test is conducted. All test packages shall be
given serial numbers and listed in order to keep track of the status of
tested and untested parts (Refer to Attachment 'I')

7.2.3 The testing manifold must be tested prior of usage by applying 1.2 times
the maximum test pressure requirement

7.2.4 All pressure gauges used in this test package and in the system for
purpose of testing shall be calibrated and the frequency of calibration
shall not exceed one month. The test pressure shall lie between 30% and
80% of the pressure gauges reading scale. The quantity of pressure
gauges shall be decided depending on the size of the network to be tested

7.2.5 Normally a minimum of two pressure gauges shall be placed as a

minimum on the system and far away from the pressurizing equipment

7.2.6 The pressure relief valve shall be tested, dated and tagged one week prior
to test. The validity of calibration of PRV is only for one week. The relief
valves shall be regulated to requirements of test so as to relief at 5%
above test pressure

7.2.7 The calibration labels shall be available and visible on the pressure
gauges and relief valve

7.2.8 Dry air, Nitrogen or inert gases shall be utilized as test media depending
on application

7.2.9 Oxygen, flammable and toxic gases shall never be used as test medium,
verification of test medium shall be submitted to SA as per SAIC-A-2004

7.2.10 Generally, for safety reasons, the pneumatic test shall be conducted
during daylight

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7.2.11 All safety precautions will be measured & testing area shall be barricaded
with safety signs which are to be fixed on visible places stating: "Keep
away- Pneumatic Pressure Test is in progress "

7.2.12 The piping system shall be cleaned from foreign materials/debris by

flushing and internal cleaning, flushing/internal cleanliness procedure
shall be approved by SA prior to start pneumatic test, requirement as per
SAIC – L – 2001 shall be complied

7.2.13 The tested portion of pipe work shall be properly supported and
inspected prior to test

7.2.14 Approval for pressure test application shall be issued from S. Aramco
PID inspector prior of pressure test starting

7.2.15 All openings except test medium inlet shall be closed using correct rating
plugs, caps or other suitable means

7.2.16 All joints shall be accessible and properly illuminated by natural or

supplemental white light

7.2.17 All joints shall be free from grease, primer, coating or any other foreign
materials that will interfere in the test

7.2.18 The following components which may be on the network, shall be

removed, replaced with temporary piece or isolated from pipe work,
according to the test package:

7.2.18.1 Orifice Plate

7.2.18.2 Filter Element
7.2.18.3 Temporary Strainer
7.2.18.4 Safety & Relief Valve (Permanent)
7.2.18.5 Rupture Disk
7.2.18.6 Expansion Joint
7.2.18.7 In-line instruments (If piping has been flushed prior to
Testing, on/off valve may be remain in line, but valve shall
be kept open during test and flushing activities)
7.2.18.8 Pressure Gauge (Permanent)
7.2.18.9 Temporary Gauges
7.2.18.10 Stream Trap
7.2.18.11 Mixing Nozzle & Mixers
7.2.18.12 Check Valve discs: shall be removed and securely attached
to the outside of check valve prior to pressure test
7.2.18.13 Soft Seated ball and plug valve

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7.2.19 The tested portion of the network shall be isolated by using blind flanges
or end caps

7.3 APPLICATION OF PRESSURE:-

Application following document shall be attached and comply prior to
start any pneumatic test.
SAIC-A-2010
SAIC-L-2017
SAIC-A-2009
SAIC-A-2020
SAIC-A-2020
SAIC-A-2021
SAIC-A-2001
SAIC-A-2002
SAIC-A-2005
SAIC-A-2007
SAIC-A-2009

7.3.1 Test pressure shall be 110% of design pressure, with the following
limitations:
*minimum pressure 30 kPa (4.35 PSI)
*maximum pressure 701 kPa (101 PSI)

7.3.2 The pneumatic test pressure shall be increased steadily and gradually in
stages to allow time for: material to strain and for visual inspection of
leakage. It should not be raised directly to the test pressure. The
incremental stages will be as follows:

7.3.2.1 Preliminary leak test: System is pressurized to 175kPa

(25PSI) or 50% of the strength test pressure whichever is
lower

7.3.2.2 Leak Visual Inspection: Check for any leak in network

7.3.2.3 Step pressure rise: After successful preliminary leak test,

pressure is applied to the system in steps such that: the
increment is not greater than 1/10 of the test pressure and
for a hold period not less than 10 min (10 intervals each
interval for 10min duration)

7.3.2.4 After reaching the value of strength test pressure (154 PSI),
the pressure shall be hold inside network for not less than
30min. and the pressure gauges are monitored, in order to
check the integrity of the welded joints

7.3.2.5 The pressure shall then be reduced to a leak test pressure of

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35-70 KPa (5-10 PSI) for leak testing using bubble solution.
The bubble solution shall be compatible with temperature
conditions of test (Between 4 to 52 0C). (ASME Sec V
Article 10, Paragraph I-1032b)

7.3.2.6 The leak test shall be held, and bubble solution shall be
applied for each joint. The presence of continuous bubble
growth indicates leakage in the examined joint

7.3.2.7 The defective joints shall be repaired and the test procedure
shall be repeated until successful results are achieved

7.3.2.8 For flanged joints, masking tape shall be applied to the

joint circumferentially with a pin hole in the tape for
detecting leak. After tape application soap (bubble solution)
shall be applied
7.3.2.9 Reinforcing pads of welded branch connections shall be
pneumatically tested with air at 25 PSI through a tapped
vent hole (weep hole), and examined for leaks using soap
solution at a reduced pressure of 3-5 PSI. The tapped vent
hole shall be packed with heavy grease after the completion
of the Test

7.3.2.10 Inspection for leakage or other visible defects shall be done

on all joints and connections. S.O. QC inspector shall
perform this inspection with the presence of S. Aramco PID
inspector

7.3.2.11 If the test result is successful permission for discharging the

test media from the system shall be issued by S. Aramco
PID inspector

7.4 DEPRESSURIZATION:

7.4.1 Release of pressure is done on the downstream side of the check valve

7.4.2 The depressurization valve shall be located inside the barricaded area for
purpose of testing

7.4.3 The test media (air or N2) shall be discharged safely and gradually (as per
SAEP-327) through depressurization valve

7.4.4 The pressure gauges are monitored throughout the depressurization until
a zero reading is indicated

7.5 TEST COMPLETION:-

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7.5.1 After completion of test, all accessories and equipments, which were on
the pipe network for the purpose of testing, shall be removed and
permanent equipments/fittings shall be reinstalled

7.5.2 Blind flanges or end caps used for the purpose of testing shall be removed

7.5.3 The test manifold shall be disconnected from the system

7.6 INSPECTIONS:-

Work execution Inspection and Test shall be monitored and witnessed as

per Saudi Aramco Typical Inspection Plan (SATIP) and recorded in the
Saudi Aramco Inspection check list (SAIC) as applicable.
The limited reference SATIPs and SAICs, listed in this M.S, are as a
minimum. A review of full set of SATIPs and SAICs is required.
S.O.L shall issue a written RFI 24 hour in advance of test/inspection to
permit SAPMT to verify the readiness of the test/inspection and to inform
SAPID Inspector in advance. The test packages documents shall be
submitted to S. Aramco at least 24 Hrs prior to each time the hydro test is
conducted.

8. LOSS PREVENTION

All activities shall be preformed safely in accordance to the S.O.L approved

Safety Manual & Procedure to minimize injuries. The installers shall wear the
relevant Personal Protective Equipments (PPE) as per the safety guidelines.

All safety precautions will be taken & testing area shall be barricaded with
safety signs which are to be fixed on visible places, e.g. "Keep away- Pneumatic
test is in progress ".

9. ATTACHMENTS

Attachment ‘I’ Pneumatic Test Packages List & Status

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