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A7
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 & other applicable tests (Ferrite Content, etc)
B) Can identify weld repairs & modifications after acceptance and any
need for follow-up pressure testing or NDT. Also, backlogs.
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
SAEP-1160,
Section 6
(Data Elements)
A6 Other sections for special process control procedures (per Sch Q) detailreferences, responsibilities, definitions & procedure reqmts.
Sch Q,Para 3.1
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQPT CODE SYSTEM ID.
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
LAYOUT DRAWING NUMBER
PLANT N
REV. NO.
WORK PERMIT
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION
SCHEDULED INSPECTION DATE & TIME MH's SPENTQUANTITY INSP.ACTUAL INSPECTION DATE & TIME
SAUDI ARAMCO USE ONLYTRAV
EC / PMCC / MCC NO.PURCHASE ORDER NUMBER
A
SAUDI ARAMCO ACTIVITY NUMBER
CONTRACTOR INSPECTION LEVELSAUDI ARAMCO INSPECTION LEVEL
SAUDI ARAMCO TIP NUMBER
ITEM
No.ACCEPTANCE CRITERIA RE-INSPASSREFERENCE FAIL N/A
Sch Q,
CPI clause
A5An attachment section exists listing applicable QC forms & records.
(ISO 9001:2000, Para. 4.2.4a)
Sch Q,
Para 3.1
Sch Q,Para 3.1
Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)
A3
A) An approval section exists to document adequacy prior to use.
B) Revision control section exists to document procedure changes.
(ISO 9001:2000, Para. 4.2.3a)
Sch Q,
Para 3.1
A1
Procedure Scope Section contains a section for Quality Goals &
Continuing Process Improvement, customer satisfaction, & lists
quality goals (following example provided):When made evident through documentation of field deficiencies or when
requested by SA, revisions to improve this document and other quality
awareness corrective and preventive actions shall be taken in a
Continuing Process Improvement (CPI) effort targeting Project Quality
Goals such as Customer Satisfaction, reduction of costly rework, &
Savings through Quality. Such Revisions shall correct errors,
deficiencies, omissions or detail more thoroughly quality elements to
provide adequate field instruction in an effort to meet SA Stds & Industry
Best Practices for Pressure Testing.
Alternative: QP covers this & regu lar Quality Review shall identify
defic iencies for Procedural Improvem ent & corrective action.
A2 Procedure is project specific, identifiable by Budget Item (BI) or JobNumber, Contract Number & Project title & traceable to Quality Plan.
P 1 f 30
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
B
General Requirements
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
B1
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 precautions (*Use a test symbol legend)
Relief valve capacity, testing and installation
Pressure gages and recorders calibration records
SA Safety Instruction Sheet (critical piping), Pressure Test Report
Copies of P&ID & ISOs of the piping system to be pressure tested
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
SAEP-1160,
Section 8
See Note 1 &
SAIC-A-2003
B2
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
Test medium (water, treated water, lube oil, etc) and cleanliness Test pressure duration and limitations
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)
GI-2.102
Attachment 1Section 2
SAES-A-004,
Section 5.7
B3
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)
No block valves exist in the relief valve inlet or outlet
Relief valve is located near test pump or medium supply
Two or more calibrated pressure gauges are used (30 day rule) Pressure gauges are properly located with block/bleed valves
Pressure gages at pump or supply are clearly visible to operator
Blowdown & Isolation valves exist on the test piping
Blowdown areas are designated for safety (Warning signs)
Manifold is certified/tested to 1.2 times maximum test pressure.
GI-002.102,
Attachment 1,
Section 5See Note 2 &
SAIC-A-2009
B5Procedure Equipment or Safety section details regular safety
inspections & maintenance of test equipment perSAIC-A-2009.
See Note 2 &
SAIC-A-2009
B4
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 pressure testing
procedure shall be kept at test sites. Test crews and those personnel
responsible for pressure testing are trained and aware of GI and
procedural requirements to assure safe pressure testing
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B6
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 procedureshall be designed to protect corrosion-susceptible matls.
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)
SAES-A-007,
Section 5.7
B7
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)
B) If Valve Field Testing is included in procedure (see API 598), add:
Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure
Test & Backseat Test (SAES-L-108, Section 4.7.6)
Procedure clearly states differences between test types
SAES-L-150,
Section 4
See also
Attachment 2
SAES-L-150,
Section 8
C Pipeline Pressure Testing Applications (Include in procedu re if applicable per scop e)
C1
Pipeline Strength Tests for New Pipelines are detailed in procedureand 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.
C) Strength Test 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 detai ls calculat ion checks and responsib i l i tes
SAES-L-150,
Section 8
C3
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)
minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors)
B) Actual wall thickness & flange rating determines test pressure.
Work is p er latest edit ion o f SAEP-310 requirements for the Repair
& Maintenance of Pipel ines.
SAES-L-150,
Section 8
C2
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.
B) A 24-hour recorded tightness test is done 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 detai ls Tightness Test parameters
C4Procedure details: Valve Field Pressure Test Applications, Test
Facility, & considerations before, during, and after testing:
See item D4
below
D On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
D1
Procedure has an On-Plot Piping Pressure Testing Matrix.
See Attachment 1. This shall cover all tests for On-Plot activities and,
when reviewed with the Pressure Testing Specification, shall provide
adequate instruction for Test Package Development & On-Plot pressure
testing & other related testing activities including all Utilities (sewer,
water), Firewater & Plumbing systems.
Provide clear On-Plot test bound aries & test reqmts .
Define Test
Workscope
& Specifications
Sch Q, Att IV,
Table 2.1
D2
Procedure states: A hydrostatic strength testshall be applied to all
newly constructed plant piping prior to initial operation per the
applicable SA requirements and ASME B31.3 or ASME B31.1 except as
noted. (Detai l Exceptions in pro cedure)
SAES-L-150,
Section 5
D3
Vessel Trim receives a strength test except for vessel trim in Utility
services tested at 150 psi and less (conduct a service test).
Clearly identi fy Vessel & Piping Code test boun dary l imits.
SAES-L-150,
Section 5
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
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D4
Procedure details: Valve Pressure Test Applications, Test Facility, &
considerations before, during, and after testing:
A) Applications include Field hydrotesting perSAIC-L-2042 that followSAES-L-108, API 598, & ASME B16.34 requirements. Valves require
body & seat closure tests per SAES-L-108, Sect. 4.
B) Valve Testing Facility meets SAIC-L-2031 (See Sections D & J).
C) In-line testing of valves (body test, seat test restrictions & calcs)
D) Post Test draining, cleaning, inspection and preservation details shall
be included whenever valves without drains are tested in-line.
Valve Testing is inclu ded in pressu re testing procedure. See Att 2
(API 598 Definit ions, Consid erations for Tests against Valve Seats,
Post-Test Valve cavity cleaning & ins pection)
SAES-L-150,
Section 5.11
& SAES-L-108,
Section 4.7
SAES-L-150,
Section 7.4
D5Sampling piping systems are pressure tested as an integral part of the
piping or equipment to which it is connected.
SAES-L-150,
Section 5
D7
Underground process plant piping is tested as follows:A) Prior to any backfilling for2 hours minimum (Check 100% joints)
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
SAES-L-150,
Section 7.4
D6Lube and seal oil piping is strength tested in its own fluid at the greater
of 1.5 times design pressure or 100 psig (for 30 minutes).
D8
Jacketed piping exams & hydrotest sequence are detailed in the test
procedure (code references apply):
A) Inner lines are accepted & all exams (visual, NDE, etc) are complete
& acceptable prior to strength testing internal piping.
B) Inner piping joints are 100% visually accessible for pressure test
C) Outer pipe split fitting design for branches allows joint access.
D) Outer pipe is centered with spacers seal welded to inner pipe.
Jacket material design & instal lat ion sequence meets code.
E) Service testing can be performed on the outer steam piping.
Detai l any ch art recorder use (24-hour supp lemental test)
ASME B31.3,
Section 345.2.5
SAES-L-150,
Para 5.12
D9
Tie-In butt welds are detailed in hydrotest procedure as follows:
A) Tie-in butt welds (to new or existing pipe) are strength tested
B) Strength Test Pressure is based on minimum Code requirements if
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.
SAES-L-150,
Section 5
D11
RETESTING of Piping systems that have already successfully passed
a pressure test require a second pressure test if/when:
A) Major Repairof Piping system subject to new welding activity.
Note: This includes modifications & pressure boundary work.
B) Post-weld Heat Treatment (PWHT) is specified for that line.
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 detai ls retest ing reqm ts & responsib i l i t ies, and the
Database has capabil i ty for tracking su ch repairs.
SAES-L-150,
Section 5.8
D10
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.
C) The test 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 Flushin g/Cleaning Metho ds
D12
Open-ended Piping (drains, vents & piping downstream of PZVs)
discharging directly to atmosphere (max internal pressure 10 psig) is not
pressure tested. Test Package lists "Visual exam only".
SAES-L-150,
Section 5.9
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001
D13
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 constru cted water supply system s are disinfected per GI-
0151.006, SA Sanitary Co de, Chapter SASC-S-01. The proc edure
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)
SAES-S-060,
Para. 103.5.3.3
D14
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
nitrogen (Oxygen prohibited) at test pressure not less than 1- times
maximum working pressure, but not less than 60 psi (413kPa) for a
period of not less than thirty (30) minutes.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 building premises when there is reason to believe that it has become
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.
SAES-S-060,
Para. 103.5.3.3,
Para 1204.3.2,
Para. 103.5.5.1
D15
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
nitrogen (Oxygen prohibited) at test pressure not less than 1- times
maximum working pressure, but not less than 60 psi (413kPa) for a
period of not less than thirty (30) minutes.
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 building premises when there is reason to believe that it has become
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.
SAES-S-060,
Para. 103.5.3.3,
Para 1204.3.2,
Para. 103.5.5.1
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
Page 5 of 30
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SAES-L-150,
Section 9.1
E Service Test, Leak Test, Minor Repair & Other Applications (Include & detai l Service Test l imitat ions per sco pe)
E1
In New Plants, Low pressure steel piping in water, instrument air, plant
air, inert gas (Nitrogen, etc.) & steam systems operating at 150 psig or
lower are Service Tested (except FW systems).
Vessel Trim & Samplin g l ines also receive a Service test.
SAES-L-150,
Section 9.3
E3
Service Test socket welded piping on Tie-in work & repairs (inExisting Facilities) if Operations Engineering Unit determines
hydrostatic test is impractical & the following requirements are met:
A) A request of NDT in lieu of pressure testing is processed.
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).
SAES-L-150,
Section 9.2
E2
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 NDE requirements, followed by Service Test.
Seal weld repairs are not do ne on Sch . 40 galvanized joints
E4
Revalidation Tests in Existing Facilities ensure test pressures are the
minimum required by ASME B31.3. Actual wall thickness readings
(less than 30 days old) and verified flange rating is taken into
consideration when calculating the test pressure.
SAES-L-150,
Section 7.5
F Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirem ents into the procedure)
F1
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.
See Attachm ent # 2. Cleaning and flushing method s are
incorp orated into the procedu re & test packages. Valve cavity (low
point) draining, dryin g, cleaning & reinsp ection measures shall be
detai led where no low po int drains exist.
SAES-L-350,
Section 15
F2
The general flushing medium is plant/ process water or raw water. Fire
water may be used where process water is not available. Sea water isnot acceptable. Water for hydrostatic test with pH less than 6 and/or
SRB counts greater than 10 per ml is unacceptable. Treat test fluid to
control corrosion and bacteria when applicable.
Emplo y regular water analysis, maintain certs and records .
SAES-A-007
Section 4
F3
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
B) Lay-up per 60-day rule (14 days on exchangers)
Wet, Dry, Inert Gas & Ambient Methods are detailed in procedure
Boiler Layup is per SAEP-1026, Other methods are CSD approved
Procedure c an uti l ize SAES-A-007, Section 5 in entirety
SAES-A-007
Section 5
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
Review Procedure - Pressure Testing (All Applications)
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
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F4
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) Test water pH is 10.0 to 11.0 (add approved soda ash/caustic)
C) Treat test water with oxygen scavenger (4-day contact rule)
D) Treat test water with biocide (14-day contact rule) and lay-up
Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods
Procedure c an uti l ize SAES-A-007, Section 6 in entirety
SAES-A-007
Section 6
F5
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 non-metallic systems (e.g., PVC pipe).
D) For Dry Gas & Refined Hydrocarbon Product Pipelines, oxygen
scavenger is added to test water, use batching scrapers & nitrogen slugto separate contacting treated water (Plant piping exempt)
Lay-up by drying to dew point of -1C for corrosion control or as
specified by proponent within 10 days after test & maintained dry.
Procedure c an uti l ize SAES-A-007, Section 7 in entirety
SAES-A-007
Section 7
SAES-A-5.5.4
G Detailed Pressure Testing Procedure Requirements (Include applicable requirem ents)
G1
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.
Note: Pressure Test diagrams can consis t of the fol lowin g:
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)
SAES-A-004,
Section 5.6
G3
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
C) Block valve isolation is severely restricted & supported by calcs.
Fabricated test implements are rated, marked & insp ected
SAES-A-004,
Para 7.3
G2
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 & Cert i f icate) is required. The sketch
l ists detai led inform ation/rat ings of al l com ponen ts. Manifolds
receive unique numb ers and records are kept.
G4
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.
Inspectors check valve l ineup & posi t ion pr ior to test ing.
SAES-A-004,
Para. 8.1.3
G5
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 314 psi)
B) Valves do not leakby (Successfully passed a seat closure test)
C) Both sides 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.
SAES-A-004,
Para 7.3 &
Attachment 2
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
Page 7 of 30
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SAES-L-150,
Section 7.1
Attachment 2
G7
Components in new piping systems that interfere with filling, venting,
draining or flushing are not installed until after line flushing & pressure
testing are complete. (orifice plates, flow nozzles, sight glasses,
venturies, metering and other in-line equipment.
List i tems in procedure and on reinstatement checkl is t
SAES-A-004
Para 7.1.4
G6
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)
Valve pressure rating (1.5xASME B16.34 value, round up 25)
Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design
Internal FBE Coating pressure rating is known, listed & considered
Ensure l im it ing factor s are l isted (SIS Sheets/test reports)
Prevent overpressurizat ion & damage! See Excel Sheet 3
G8
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.
F) Other sensitive equipment designated by SA Inspector*
*Soft seated valves & co ntrol valves are instal led AFTER lines have
been tho roug hly flus hed (SAES-A-004 Para 7.1.3)
List i tems in procedure and on reinstatement checkl is t
SAES-A-004
Para 7.2
SAES-A-004
Para 5.5.1
G9
Vent & Drain installations for testing purposes are as follows:
A) Vents are provided at all high points in the piping system.B) Drains are provided at all low points in piping system excluding
submarine and buried pipelines. (Dead legs are no t instal led)
This is a Pre-Hydrotest check l ist item verif ied by Inspection
SAES-L-150,
Section 6
G11
All joints (threaded, welded & flanged) are exposed for visual leak
detection during the strength test. External coating/priming of such joints
is not allowed unless approved by ID Manager & Proponent
SAES-L-150,
Section 7.3
G10
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.
Contractor m aintains l ist of rel ief valves and has a SA approved
vendor or system to do weekly cal ibrat ions. Inspecto rs witness
rel ief valve calibrat ions
G12
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). Inspection time may exceed test times listed in SIS sheets &
Hydrotest reports (30 minute is a m inimum).
Inspectors shall com plete inspection before tests are ended.
SAES-L-150,
Para. 5.12.2
G13
Temporary supports & other support considerations for above ground
piping installations during hydrotest are as follows:
A) Where required to prevent damage to system
B) As highlighted in the approved hydrotesting 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.
SAES-L-150,
Section 6
RE-INSP ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Page 8 of 30
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SAES-A-004
Para 8.1.1
G15
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".
Test water reuse is restr icted to ensure cleanliness & qu ali ty
SAES-L-150,
Section 11
G14
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
pressure drops. Test crews shall allow additional time (15 minutes
average) for air bubbles trapped in test water to vent. After such time &
fluid levels drop at vents, a final slow fill is done.
Justi f icat ion fo r Note: Thou sands of manh ours are lost due to test
fai lures unti l steps are taken to adequately train test crews to stop
rushing dur ing f i l l ing, assure adequate t ime for proper v ent ing of
air & use a slow fin al f i l l techniq ue.
G16
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
closed & the test pump disconnected. (Use Bold Letters)
Note: The isolation valve downstream of the manifold shall then be
opened after the pump has been disconnected.
SAES-A-004,
Para. 8.1.2
SAES-A-004,
Section 5.7
G17
Pressure gages & recorderrequirements 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.
D) Two gages (accuracy of each within 5%) are used in testing.
E) When large systems are tested, additional gages are required.
A curr ent l ist of gauges (records ) & cal due dates are kept.
SAES-A-004
Para 7.1.5
HHydrotesting (Sample Package & reinstatement):
(Include/reference reinstatement requirements that apply)as referenced
G18
If strength test is not practical, it can be substituted with 100% RT &
subject to approval by Inspection Department Mgr. for new projects.
Process a request of NDT in l ieu of pressu re testing.
H1
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)
Sample SA Safety Instruction Sheet & Pressure Test Report Form
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 samp le test package & procedure for SA approval.
SAES-L-310,
Section 22
RE-INSP ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Page 9 of 30
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10/30
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001
H2
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.
C) Items such as instrument air tubing, check valve discs that 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 detai ls the reinstatement effort
SAES-L-310,
Section 22
REMARKS:
Note
1
Pressure Test Procedure (SAES-A-004 Definition): Information assembled to ensure all requirements listed in GI-0002.102 , all refere
SA & Industrial standards are met. Per SAES-A-004 Definition, test packages are part of the Pressure Test Procedure. 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). Sma
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.
Note
2
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)
2. Sample Hydrotest Package Per SAIC-2003 3
Hydrotest Data Mgmt & Tracking Database per 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
3
Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes a
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.
Note
4
Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) & adoptio
Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality. This section
not repeated in other "Review Procedu re" type special proc ess checkl ists, yet is intended for al l .
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
1-Dec-06 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP
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ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA ProjectsAttachment 2 - Pressure Testing Inspection Guide
REFERENCE DOCUMENTS:
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing
2. SA General Instruction Manual GI-002.102 (July 22, 2001) Pressure Testing Safely
3. SAEP-1160 (17 July 2006) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects
4. SAES-A-004 (30 March 2005) General Requirements for Pressure Testing
5. SAES-A-007 (5 October 2005) Hydrostatic Testing Fluids and Lay-Up Procedures
6. SAES-L-108 (21 December 2005) Selection of Valves
7. SAES-L-150 (30 September, 2003) Pressure Testing of Plant Piping and Pipelines
8. SAES-L-310 (30 September, 2003) Design of Plant Piping
9. SAES-L-350 (30 September, 2003) Construction of Plant Piping
10. SAES-S-010 (31 December 2002) Sanitary Sewers11. SAES-S-020 (30 November 2002) Industrial Drainage and Sewers
12. SAES-S-030 (August 2005) Storm Water Drainage Systems
13. SAES-S-040 (31 December 2003) Saudi Aramco Water Systems
14. SAES-S-050 (30 August 2000) Sprinkler and Standpipe Systems in Buildings
15. SAES-S-060 (28 January 2004) Saudi Aramco Plumbing Code
16. SAES-S-070 (28 September 2005) Installation of Utility Piping Systems
Contractor / Third-Party Saudi AramcoConstruction Representative* PMT Representative
Name, Initials and Date:Work is Complete and Ready for Inspection:
Name, Initials and Date:T&I Witnessed QC Record Reviewed W o
QC Inspector PID Representative
Name, Initials and Date:Performed Inspection Work / Rework May Proceed
Name, Initials and Date:T&I Witnessed QC Record Reviewed W o
QC Supervisor Proponent and Others
Name, Sign and Date:Quality Record Approved:
Name, Organization,
Initials and Date:
T&I Witnessed QC Record Reviewed W o
*Person Responsible for Completion of Quality Work / Test Y = YES N =
SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MEPROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE
7/22/2019 SAIC-A-2001 Rev 2
12/30
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 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
& DURATION
TEST CONSIDERATIONS & NOTES
Process
Piping
As Calculated*
30 mins (min)
Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test
required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu o
pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process requesper 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
Systems
See Notes
30 mins (min)
*Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psi
whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be 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 (chec
low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.
Underground
A) Process Piping
B) Utility Piping
As Calculated
See Notes
A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B) P
SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.
ju s ti fi ab le (safet y , bac k-fi ll ed lin e) a 24 h r re cord ed tes t (Ch ar t Record er ) is req d.
Flare Lines
(24" & above)
See Notes
30 mins (min)
Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested
pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
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 h
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 Notes30 mins (min)
Tested to 1.5 times the differential external pressure, but not less than 15 psig.
Air & Inert Gas
(150 psig max)
SERVICE TEST &
Soap Bubble Test
30 mins (min)
Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joint
are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiv
Service tests and final gasket installation.
LP Steam
(60 psig max)
SERVICE TEST
30 mins (min)
Coordinate with system Service tests and construction completion.
Weld-Plus-Ends
(SAIC-A-2016)
Soap Bubble Leak
Test at 5-10 psig
Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus
between the gasket and the seal weld. It shall be examined for leaks using a soap solution.
Existing Plant
Piping
Incl. Tie-Ins
As Calculated*
30 mins (min)
For revalidation purposes of existing plant piping, the test pressure shall be minimum required by t
Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined a
taken into consideration when calculating the test pressure. In case of flanged tie-in connections,
flange tester is utilized to conduct hydrostatic testing of flange butt weld.
RETESTING
REQMTS
See Notes Systems that already passed a successful pressure test require RETEST IF subjected to new
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 EXISTING
PIPING
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 press
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
Piping
EXEMPT,
VISUAL EXAM
Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
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 Lines
As Calculated*
30 mins (min)
Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
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.
Internally FBE
Coated Lines
As Calculated*
30 mins (min)
For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not excee
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.
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).
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Sampling Lines See Note Test as an integral part with the piping or equipment to which it is connected.
Vessel & Tank
Trim (Piping)
See Note Test separately (separate package) as required. Exemptions include sight glasses &
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-MountedPiping (Vendor)
EXEMPT IF TESTED BY VENDOR
per 01-SAMSS-010
(exceptions noted)
1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
2. When code repairs are made to skid-mounted piping to correct misalignment,
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
New Valves
See Note All new valves designated for isolation service (as specified by the Proponent) shall b
subjected to high pressure hydrostatic seat test prior to installation in line.
Exception See Note Low pressure pneumatic seat test at 5 psig shall be substituted for high pressurehydrostatic 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(Checklist Item D4)
See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be equal
those that the valves were originally purchased to. All resilient (soft) 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 uniquID 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 (Pipin
System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (inte
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-situprior 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 tan
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 SA
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 ofUniform Plumbing Code (UPC). Exception
to UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESSPotable 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 t
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.
6.13 Miscellaneous Building Services Piping - Steam & condensate piping outside the jurisdiction of ASME B31.3, heating & cooling water pipi
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.
QR NUMBER
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 MECH-
Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 MECH-
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 withliquid.
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 applicabl
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 a
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 -1C 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 alternat
method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems removing trapped liqu
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
more than 810 kPa (115 psi). Safety precaution shall be considered in consultation with Area Loss Prevention Divisio
when this method is used. Repeat PASB until cleanliness is verified by observing the absence of any solids impact on
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 lis
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 du
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. Se
water is not acceptable. When flushing stainless steel lines, chloride ion content shall be less than 50 mg/L. Afterflushing, piping systems shall be completely drained, dried to a dew point below -1C 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.
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.
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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 598Table 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 h drotest at 450 si a ainst the valve seat because over ressurization 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 &
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
Example #2 (Spec 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 allowabl
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 flange
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.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.
Rev 2 31-Dec-05SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 MECH-
Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
Page 15 of 30
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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 Factorfrom Table A-1A or Table A-1B (Quality factor for API 5L Seamless Pipe is 1.00),therefore E = 1.00
D = outside diameterof 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 or1,723 psi is rating for limiting factor for 12 pipe
Calc for 24 pipe ... P=.328 x (2)(35,000)(0.9) / 24 = 861.33 or861 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.
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBERSAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 MECH-
Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
RE-INSP ITEM
No.ACCEPTANCE CRITERIA REFERENCE FAIL N/A
General Requirements
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
PASS
WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
SAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-
SAUDI ARAMCO INSPECTION CHECKLIST
PROJECT TITLE
Procedure Equipment or Safety section details regular safety
inspections & maintenance of test equipment perSAIC-A-2009.B5
GI-002.102,
Attachment 1,
Section 5See Note 2 &
SAIC-A-2009
B
B1
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 precautions (*Use a test symbol legend)
Relief valve capacity, testing and installation
Pressure gages and recorders calibration records
SA Safety Instruction Sheet (critical piping), Pressure Test Report
Copies of P&ID & ISOs of the piping system to be pressure tested
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
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 pressure testing
procedure shall be kept at test sites. Test crews and those personnel
responsible for pressure testing are trained and aware of GI and
procedural requirements to assure safe pressure testing
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
Test medium (water, treated water, lube oil, etc) and cleanliness Test pressure duration and limitations
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)
B4
B3
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)
No block valves exist in the relief valve inlet or outlet
Relief valve is located near test pump or medium supply
Two or more calibrated pressure gauges are used (30 day rule) Pressure gauges are properly located with block/bleed valves
Pressure gages at pump or supply are clearly visible to operator
Blowdown & Isolation valves exist on the test piping
Blowdown areas are designated for safety (Warning signs)
Manifold is certified/tested to 1.2 times maximum test pressure.
B2
GI-2.102
Attachment 1Section 2
SAEP-1160,
Section 8
See Note 1 &
SAIC-A-2003
See Note 2 &
SAIC-A-2009
SAES-A-004,
Section 5.7
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
RE-INSP ITEM
No.ACCEPTANCE CRITERIA REFERENCE FAIL N/APASS
WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
SAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-
SAUDI ARAMCO INSPECTION CHECKLIST
PROJECT TITLE
SAES-L-150,
Section 8
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)
minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors)
B) Actual wall thickness & flange rating determines test pressure.
Work is p er latest edit ion o f SAEP-310 requirements for the Repair
& Maintenance of Pipel ines.
Define Test
Workscope
& Specifications
Sch Q, Att IV,
Table 2.1
Pipeline Pressure Testing Applications (Include in procedu re if applicable per scop e)
On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
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.
B) A 24-hour recorded tightness test is done 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 detai ls Tightness Test parameters
Procedure has an On-Plot Piping Pressure Testing Matrix.
See Attachment 1. This shall cover all tests for On-Plot activities and,
when reviewed with the Pressure Testing Specification, shall provide
adequate instruction for Test Package Development & On-Plot pressure
testing & other related testing activities including all Utilities (sewer,
water), Firewater & Plumbing systems.
Provide clear On-Plot test bound aries & test reqmts .
SAES-L-150,
Section 8
Procedure details: Valve Field Pressure Test Applications, Test
Facility, & considerations before, during, and after testing:
See item D4
below
D2
Procedure states: A hydrostatic strength testshall be applied to all
newly constructed plant piping prior to initial operation per the
applicable SA requirements and ASME B31.3 or ASME B31.1 except as
noted. (Detai l Exceptions in pro cedure)
SAES-L-150,
Section 5
SAES-A-007,
Section 5.7
C
D3
Vessel Trim receives a strength test except for vessel trim in Utility
services tested at 150 psi and less (conduct a service test).
Clearly identi fy Vessel & Piping Code test boun dary l imits.
C1
Pipeline Strength Tests for New Pipelines are detailed in procedureand 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.
C) Strength Test 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 detai ls calculat ion checks and responsib i l i tes
C2
D
C3
C4
SAES-L-150,
Section 4
See also
Attachment 2
SAES-L-150,
Section 8
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)
B) If Valve Field Testing is included in procedure (see API 598), add:
Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure
Test & Backseat Test (SAES-L-108, Section 4.7.6)
Procedure clearly states differences between test types
B6
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 procedureshall be designed to protect corrosion-susceptible matls.
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)
SAES-L-150,
Section 5
D1
B7
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
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No.ACCEPTANCE CRITERIA REFERENCE FAIL N/APASS
WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
SAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-
SAUDI ARAMCO INSPECTION CHECKLIST
PROJECT TITLE
SAES-L-150,
Section 5.9D12
Open-ended Piping (drains, vents & piping downstream of PZVs)
discharging directly to atmosphere (max internal pressure 10 psig) is not
pressure tested. Test Package lists "Visual exam only".
D11
RETESTING of Piping systems that have already successfully passed
a pressure test require a second pressure test if/when:
A) Major Repairof Piping system subject to new welding activity.
Note: This includes modifications & pressure boundary work.
B) Post-weld Heat Treatment (PWHT) is specified for that line.
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 detai ls retest ing reqm ts & responsib i l i t ies, and the
Database has capabil i ty for tracking su ch repairs.
SAES-L-150,
Section 5.8
ASME B31.3,
Section 345.2.5
D9
Tie-In butt welds are detailed in hydrotest procedure as follows:
A) Tie-in butt welds (to new or existing pipe) are strength tested
B) Strength Test Pressure is based on minimum Code requirements if
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.
SAES-L-150,
Section 5
D8
Sampling piping systems are pressure tested as an integral part of the
piping or equipment to which it is connected.
SAES-L-150,
Section 5
SAES-L-150,
Section 5.11
& SAES-L-108,
Section 4.7
D6Lube and seal oil piping is strength tested in its own fluid at the greater
of 1.5 times design pressure or 100 psig (for 30 minutes).
SAES-L-150,
Section 7.4
D7
Underground process plant piping is tested as follows:A) Prior to any backfilling for2 hours minimum (Check 100% joints)
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
SAES-L-150,
Section 7.4
Jacketed piping exams & hydrotest sequence are detailed in the test
procedure (code references apply):
A) Inner lines are accepted & all exams (visual, NDE, etc) are complete
& acceptable prior to strength testing internal piping.
B) Inner piping joints are 100% visually accessible for pressure test
C) Outer pipe split fitting design for branches allows joint access.
D) Outer pipe is centered with spacers seal welded to inner pipe.
Jacket material design & instal lat ion sequence meets code.
E) Service testing can be performed on the outer steam piping.
Detai l any ch art recorder use (24-hour supp lemental test)
D10
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.
C) The test 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 Flushin g/Cleaning Metho ds
SAES-L-150,
Para 5.12
D4
Procedure details: Valve Pressure Test Applications, Test Facility, &
considerations before, during, and after testing:
A) Applications include Field hydrotesting perSAIC-L-2042 that followSAES-L-108, API 598, & ASME B16.34 requirements. Valves require
body & seat closure tests per SAES-L-108, Sect. 4.
B) Valve Testing Facility meets SAIC-L-2031 (See Sections D & J).
C) In-line testing of valves (body test, seat test restrictions & calcs)
D) Post Test draining, cleaning, inspection and preservation details shall
be included whenever valves without drains are tested in-line.
Valve Testing is in cluded in p ressure testing pro cedure. See Att 2
(API 598 Definit ions, Consid erations for Tests against Valve Seats,
Post-Test Valve cavity cleaning & ins pection)
D5
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05
RE-INSP ITEM
No.ACCEPTANCE CRITERIA REFERENCE FAIL N/APASS
WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
SAIC NUMBER DATE APPROVED QR NUMBER
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-
SAUDI ARAMCO INSPECTION CHECKLIST
PROJECT TITLE
F Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirem ents into the procedure)
E4
Revalidation Tests in Existing Facilities ensure test pressures are the
minimum required by ASME B31.3. Actual wall thickness readings
(less than 30 days old) and verified flange