SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2010)

Rev 4
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

SAIC-A-2011

PROJECT TITLE

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

31-Mar-10
DATE APPROVED

QR NUMBER

MECH-

31-Aug-11

CONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

Test Preparation - General Requirements ... USE SATR-A-2001, 2002, 2003, 2004, 2005 & SATR-A-2006 as req'd.

A1

Pressure Test Package meets Attachment 1 minimum content

requirements. (Reviewed/approved/signed). See SAIC-A-2003.
Note 1: Package contents were reviewed carefully.
Note 2: Document deficiencies are noted in package for action.

SAEP-1160,
Section 8

A2

Pre-Test Punchlisting is complete (per procedure). All "A" items are

cleared & accepted* (*Test Pkg Flow Chart is also signed off)
Note: "A" items are Pre-test Punchlist items that must be complete prior
to safe pressure testing of systems per approved procedure.

SAEP-1160,
Section 8

A3

Permanent Flange set installations are documented/accepted.

Note: Flanges that will not be disturbed after the pressure test are
marked/identified and tightened & QC records are per approved
procedure & available. See also SAIC-L-2014 & SATR-L-2001.

SAEP-1160,
Section 8

A4

System Flushing and internal Cleanliness is complete. Test Package

Flow chart is signed-off. New systems and equipment in Plants were
cleaned per approved procedures per SAES-L-350.

SAES-A-004,
Para. 8.1.2

A5

Component Safeguards (temporary removals/test exclusions) exist for

new systems to prevent damage caused by filling, venting, draining,
flushing or testing. These are itemized on Reinstatement and Pre-Test
Checklists and are found in Test Pkgs/Procedures.
See Safeguards listed in Attachment 2.

SAES-A-004,
Section 8

A6

Temporary supports shall be installed prior to hydrostatic testing, and

flushing of the piping if they were determined to be required per SAES-L150.

SAES-A-004,
Para. 8.5.2

A7

Expansion joints and spring hangers or spring supports are provided with
temporary restraints where needed to prevent excessive travel or
deformation under the test loads. (Field Verify)

SAES-L-150,
Para. 6.4

A8

All joints including welded joints are accesible and left exposed for visual
leak detection during the strength test. External coating and priming of
such joints are not allowed unless approved.
Note: This excludes joints subject to 24-hr recorded test

SAES-L-150,
Para. 7.3

A9

Work permit is obtained for pressure testing and associated work within
restricted areas, as per G.I. 2.100, Work Permit System.

G.I.-2.102,
Para. 5.1.6

A10

Equipment & appurtenances (Attachments, auxilliary equipment, etc) that

are not adequate for test pressures are isolated from test.
Provisions made to ensure that no over pressuring can occur in
equipment that is not being tested

G.I.-2.102,
Para. 5.1.7

A11

If an isolation valve is used for a test boundary, in lieu of test blind,

ensure that no overpressurization damage can occur in any equipment
beyond the isolation valve (due to valve leak-by) by:
a) Reduction of test pressure (rule = 1.1 times valve press rating)
b) Open isolation valve drain (or nearest adjacent low-point drain)
c) Relief valves placed on both sides of isolation valve. (Para. 7.3)
d) Personnel are posted during testing to identify any valve leak-by.
e) Personnel control/stop pressurization (Valve leak-by evidence).
See Remarks Section (Safety Note 1)

G.I.-2.102,
Para. 5.1.7,
SAES-A-004
Para 8.3

A12

MSDS or Chemical Hazard Bulletins is available/reviewed for all

chemicals handled (corrosion inhibitor, bactericide, chlorine, oxygen
scavenger, etc). Written procedure to safely handle chemicals during
testing & to ensure proper disposal after testing is approved.

G.I.-2.102,
Para. 5.1.9

Page 1 of 5

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation
PROJECT TITLE

ITEM
No.

Rev 4

DATE APPROVED

SAIC-A-2011

31-Aug-11

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

A 13

Personal protective equipment (PPE) is available and utilized as

shown on these sheets and bulletins for chemical handling.

G.I.-2.102,
Para. 5.2.1

A 14

Access/Egress for Test areas is marked & warning signs posted to alert
approaching personnel of pressure testing activities.

G.I.-2.102,
Para. 5.1.11

A 15

Where a road parallels within 30 m (100 ft.) of an aboveground pipeline

being tested, traffic shall be diverted or stopped during the test. If this is
not practical, the area Loss Prevention offices should be contacted to
confirm that the test can be conducted safely.

G.I.-2.102,
Para. 5.1.11

If non-Saudi Aramco facilities will be exposed in a pressure test of SA

A 16 facilities, the proponent organization of the test shall so inform the Saudi
Aramco Affairs representative prior to the test.

G.I.-2.102,
Para. 5.1.12

A 17

31-Mar-10

SAIC NUMBER

Copy of the approved pressure testing procedure & the GI-2.102 are
available at site. Test Personnel are safety trained/experienced.
Verification of Actual Test Set-up & SIS Sheet Data:

B1

Test Set-up* matches actual test arrangement (drawings).

Note 1: *Pressure Test Diagram with an appropriate Legend for
symbols, Test Manifold Arrangement (& pressure hoses/piping) show all
high points (vents), low points (drains), gage locations & provide
documentation that attests to the actual test as performed. In event of
testing accident, Loss Prevention Dept must be able to use diagrams &
sketches to recreate actual test set-up/conditions.
Note 2: Testing of multiple lines (test pkgs) on projects can be done by
proper hose arrangement, filling & venting to save time. Sketch & show
the actual hose arrangement(s) in test packages. Correct any errors in
arrangement found, initial & date sketches.

SAEP-1160,
Section 8
Bullet Item 2

B2

SIS Sheet Data (pressure, limiting factor, medium & temperature) is

checked* for accuracy against the test application and is correct.
*Note: Human error (test package calcs) is common. Inspectors
responsible for testing are able to spot gross errors & prevent unsafe
testing & overpressurization of systems & components.

SAEP-1160,
Section 8
Bullet Item 2

Test Manifold & Appurtanances (Piping, Fittings, Hoses)

C1

Pressure testing manifolds were separately pressure tested to at least

1.2 times system test pressure. (Manifold Test Report/Cert)

SAES-A-004
Para 5.5.4

C2

Pressure rating or design of test manifold components* (isolation valves,

pipe nipples, fittings) exceed system test pressure by 20%.
See Safety Note 1 in Remarks for isolation valves

G.I.-2.102,
Para. 5.1.5.5

C3

Manifold Arrangement Drawings attest to the following:

A) Fabrication was per code construction with component details listed
such as Class, size, schedule, type isolation valve, etc.
B) Maximum Safe Test Pressure Rating based on limiting factor.
C) Each test manifold is identified with a unique number (certificate)
D) Shows actual arrangement including hose configuration used
Note 1: Manifold permanent marking (unique ID #, pressure rating) is
legible, traceable & certified (Engineering support docs).

G.I.-2.102,
Para. 5.1.2.5

C4

Manifolds proposed for use on projects without detailed code

construction certification (Engineering calcs & Inspection) must be
evaluated for fitness and safety. Provide necessary details and support
test manifolds with any necessary calculations (SIS sheet) and the
appropriate visual Inspection and any necessary NDE.
Note: Unknown piping schedules can be determined by using a UT
Thickness meter. Weld quality is verified by VT or RT.

G.I.-2.102,
Para. 5.1.5.5

C5

A blow down valve of adequate pressure rating is installed to

depressurize the system safely (easily accessible to operator).

G.I.-2.102,
Para. 5.1.5.3

C6

Test piping pressure tested to at least 20 percent above test

pressure of the system under test. (Exception: Final connection
between test manifold and system under test may be tested to
maximum system test pressure only if a higher test pressure is
impractical.)

G.I.-2.102,
Section 5.1.5

C7

Paddles or spectacle blinds & other fabricated test items used to

isolate test sections are at least the same code class rating of systems
under test or are supported by appropriate code calcs. See Remarks,
Critical Safety Note 2

SAES-A-004
Para. 7.3

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

SAES-A-004,
Para. 5.6.1

QR NUMBER

Page 2 of 5

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2010)

Rev 4

31-Mar-10

SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

DATE APPROVED

SAIC-A-2011

PROJECT TITLE

31-Aug-11

WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

Test Relief Valve(s)

D1

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

G.I.-2.102,
Para. 5.5

D2

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

SAES-A-004
Para 5.5.1

D3

Relief valve(s) are tested, dated, and tagged (as valid) for a period of one
week for project pressure tests. Stickers are legible & valid.

SAES-A-004
Para 5.5.1

Pressure Gages and Recorders

E1

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

SAES-A-004
Para 8.1.5.4

E2

Pressure gages and pressure recorders are calibrated within (1) month
prior to test. Stickers applied indicate latest calibration date.

SAES-A-004
Para 8.1.5.2

E3

Avoid the following typical examples of poor practices:

Testing equipment with the test gauge located at the bottom of the
equipment reading the test pressure,including the head of test water

G.I.-2.102,
Sec.4 &
SAES-A-004,
Para 5.3

E4

All gages have a range such that the test pressure is within 30% to 80%
of the full range.

SAES-A-004
Para 8.1.5.3

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

F1

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

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

SAES-A-004
Para 5.6.3

F2

Thermocouples are installed to obtain accurate pipe metal temperature

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

SAES-L-150,
Para. 11.3

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

REMARKS: Critical Safety Note 1: Surveys of test manifolds used on projects have resulted in many findings of inadequate ratings for isolation
valves. Test manifolds for testing specific pressure rating Classes require isolation valves of the next higher class. Example: Manifolds for testing Class
300 # systems require Class 600 # isolation valves as a general rule. For Pressure tests against closed seats follow the 110% rule for safe test
pressure calculation. See ASME B16.34, Para 7.2 as applicable. Also, this same requirement must be carefully considered when determining test
pressures where an isolation valve serves as a test boundary limit and the valve seat will be pressurized. Ensure system test pressures are reduced to
110% as applicable and show the valve seat as the test "limiting factor".
Safety Note 2: Fabricated test implements of proper
code construction receive inspection and properly identification/marking for pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never
allow uninspected non-code test implement use or those that are unfit for testing (deteriorated, damaged, heavily corroded). Unsafe/unfit test
implements found are reported/removed ASAP from Company Projects.
REFERENCE DOCUMENTS:
1. SAES-A-004, General Requirements for Pressure Testing, (14-Dec-2009)
2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely, (28 October, 2008)
3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (1-Nov-2008)
4. Pro Forma Contract Schedule Q (Project Specific)
5. SAEP-1160 (2-Aug-2009)

Contractor / Third-Party
Construction Representative*

Saudi Aramco
PMT Representative

Work is Complete and Ready for Inspection:

Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

T&I Witnessed

QC Record Reviewed

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Work Verified

Name, Initials and Date:

QC Supervisor

Proponent and Others

Quality Record Approved:

Name, Sign and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 3 of 5

Work Verified

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2010)

Rev 4

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

SAIC NUMBER

SAIC-A-2011

31-Mar-10
DATE APPROVED

31-Aug-11

QR NUMBER

MECH-

Attachment 1 - SAEP-1160 Test Pkg Minimum Requirements

Page 4 of 5

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2010)

Rev 4

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Pressure Test Preparation

SAIC NUMBER

SAIC-A-2011

31-Mar-10
DATE APPROVED

31-Aug-11

QR NUMBER

MECH-

Attachment 2 - Component Safeguard Summary

Note: This Summary Checklist has been developed with concurrence of CSD

1. INSTALL THESE COMPONENTS IN LINE ONLY AFTER THOROUGH FLUSHING:

Soft seated valves & control valves (SAES-A-004, Para. 8.1.3)

2. INSTALL THESE COMPONENTS IN LINE AFTER FLUSHING & TEST COMPLETION (ON REINSTATEMENT):
Components in new piping systems which interfere with filling, venting, draining or flushing shall not be installed until after line
flushing and pressure testing are completed. This includes Procedures/Test Package Instruction or details about specific component
care as listed below (SAES-A-004, Para 8.1.4):
a) Orifice plates -- Flow nozzles -- Sight glasses (incl. vessel trim) -- Venturies -- Meters (positive displacement, turbine)
b) In-line equipment (as determined by Proponent) includes valve care (corrosion, cleaning, lay-up considerations). A list shall be
obtained by Contractor from COMPANY relative to Component Safeguards. Contractor shall request specific instruction for specific
component safeguards from Company (Proponent, SAPMT, SA Inspection)

3. INSTALL THESE COMPONENTS (EXCLUDED FROM PRESSURE TEST) ON FINAL REINSTATEMENT:

Note: The following list defines the equipment that shall be excluded from the in-situ pressure testing of the tested system. Also,
other unlisted sensitive equipment or as designated by SA Inspector can be added (SAES-A-004-Para 8.2):
a) Rotating machinery, such as pumps, turbines and compressors;
b) Strainers and filter elements
c) Pressure relieving devices, such as rupture disks and pressure relief valves;
d) Locally mounted indicating pressure gauges, where the test pressure will exceed their scale range;
e) Equipment that cannot be drained (This includes valve cavities. See Valve Care below).
f) Instrument Devices.
g) Other unlisted sensitive equipment (propose exclusion in test package)
h) Equipment designated by Saudi Aramco Inspector (Approves procedures that list specific equipment in scope)

CSD VALVE SAFEGUARDS & CARE (TYPICAL FOR AMBIENT LAY-UP)

Valve Field Hydrotest Practice (separate from line/system testing) assures adequate preservation as listed below. Valves or
other equipment that are field tested prior to installation in a pipeline, plant, or other facility are likely to experience corrosion
damage if this is not performed with adequate diligence and precautions.
a) The following applies to valve trims Type 1, 4, 6, 7, 8, and 8A and all solid Type 400 SS (13 CR) valves.
b) Plan prior field testing of valves to minimize the length of time between test and installation in the system.
c) All critical isolation valves that are tested shall be tested with water containing less than 50 ppm chlorides. The water shall
contain 0.5% by weight (5 grams per liter) Cortec VpCI 609. (Note:Chemical cost would be about $0.30 per liter. VpCI 609 is
biodegradable so there are no problems with its use. (See Environmental Protection Dept.)
d) After hydrotesting, gate valves will have their gates raised to allow full draining of water. Allow adequate drainage time. All
traces of visible water shall be removed from the valve body and seat area. Blow dry with clean compressed air.
e) Apply manufacturer approved lubricant plus 10% Cortec VpCI-329 (SAP 1000173887) added to all interior critical surfaces such
as seal areas. Ball valves shall be full operated to distribute inhibited lubricant between ball and body.

Constructed Piping Hydrotest Practice (Valve Safeguards)

a) Hydrotest plans for constructed field equipment shall be designed to minimize exposure of valves to hydrotest water. Unless it is
absolutely unavoidable, critical isolation valves (Field Hydrotested) shall be installed after completion of hydro.
b) Piping systems shall be thoroughly flushed before hydrotesting to remove wind-blown sand, construction debris, and any other
foreign matter. Flushing water shall be the same quality as the hydrotest water. Hydrotest shall be performed immediately after
flushing or the line shall be properly layed-up per SAES-A-007 Procedures (30-day rule).
c) If any 400 series (13 CR) trimmed valves are pre-installed & hydrotested in the line, utilize test gaskets and thoroughly drain test
water immediately after the test. Where complete draining is impossible (no valve body drain plug), valves shall be removed
immediately after test, dried with clean compressed air and re-lubricated before "ambient" lay-up. Ensure that there is no
debris in the seat area.
d) Any 400 series (13 CR) trimmed valves that are pre-installed and hydrotested in the line, and that have body or seat drains and
are in place when field pipework is hydrotested shall be treated with Cortec VpCI 609 by blowing into all possible valve injection
locations immediately after completion of the hydrotest and draining of all water.
e) Any 400 series (13Cr) trimmed valves that are pre-installed welded-in-place shall be liberally coated with inhibited lubricant
before final welding into the line.
f) Safeguards for 300 series (316 SS, etc) trimmed valves require similar care to assure complete cavity draining. Corrosion
inhibitors used shall be approved by CSD.

Page 5 of 5