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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

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

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

Pressure Test Package meets Attachment 1 minimum content

requirements. (Reviewed/approved/signed). See SAIC-A-2003. SAEP-1160,
A1 Note 1: Package contents were reviewed Section 8
carefully. Note 2: Document deficiencies are noted in
package for action.
Pre-Test Punchlisting is complete (per procedure). All "A" items are
cleared & accepted* (*Test Pkg Flow Chart is also signed off)
SAEP-1160,
Note:
A2 Section 8
"A" items are Pre-test Punchlist items that must be complete prior to safe
pressure testing of systems per approved procedure.

Permanent Flange set installations are documented/accepted.

Note: Flanges that will not be
SAEP-1160,
A3 disturbed after the pressure test are marked/identified and tightened & QC
Section 8
records are per approved procedure & available. See also SAIC-L-2014
& SATR-L-2001.

System Flushing and internal Cleanliness is complete. Test Package

SAES-A-004,
A4 Flow chart is signed-off. New systems and equipment in Plants were
Para. 8.1.2
cleaned per approved procedures per SAES-L-350.

Component Safeguards (temporary removals/test exclusions) exist for

new systems to prevent damage caused by filling, venting, draining,
SAES-A-004,
flushing or testing. These are itemized on Reinstatement and Pre-Test
A5 Section 8
Checklists and are found in Test Pkgs/Procedures.
See Safeguards listed in Attachment 2.

Temporary supports shall be installed prior to hydrostatic testing, and

SAES-A-004,
A6 flushing of the piping if they were determined to be required per SAES-L-
Para. 8.5.2
150.

Expansion joints and spring hangers or spring supports are provided with
SAES-L-150,
A7 temporary restraints where needed to prevent excessive travel or
Para. 6.4
deformation under the test loads. (Field Verify)

All joints including welded joints are accesible and left exposed for visual
leak detection during the strength test. External coating and priming of SAES-L-150,
A8
such joints are not allowed unless approved. Para. 7.3
Note: This excludes joints subject to 24-hr recorded test

Work permit is obtained for pressure testing and associated work within G.I.-2.102,
A9
restricted areas, as per G.I. 2.100, Work Permit System. Para. 5.1.6

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

are not adequate for test pressures are isolated from test. G.I.-2.102,
A10
Provisions made to ensure that no over pressuring can occur in Para. 5.1.7
equipment that is not being tested

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
G.I.-2.102,
rating) b) Open isolation valve drain (or nearest adjacent
Para. 5.1.7,
A11 low-point drain) c) Relief valves placed on both
SAES-A-004
sides of isolation valve. (Para. 7.3) d) Personnel are posted
Para 8.3
during testing to identify any valve leak-by. e) Personnel
control/stop pressurization (Valve leak-by evidence).
See Remarks Section (Safety Note 1)

Page 1 of 8
 MSDS or Chemical Hazard Bulletins is available/reviewed for all
chemicals handled (corrosion inhibitor, bactericide, chlorine, oxygen G.I.-2.102,
A12
scavenger, etc). Written procedure to safely handle chemicals during Para. 5.1.9
testing & to ensure proper disposal after testing is approved.

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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Personal protective equipment (PPE) is available and utilized as shown G.I.-2.102,

A 13
on these sheets and bulletins for chemical handling. Para. 5.2.1

Access/Egress for Test areas is marked & warning signs posted to alert G.I.-2.102,
A 14
approaching personnel of pressure testing activities. Para. 5.1.11

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 G.I.-2.102,
A 15
not practical, the area Loss Prevention offices should be contacted to Para. 5.1.11
confirm that the test can be conducted safely.

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

G.I.-2.102,
A 16 facilities, the proponent organization of the test shall so inform the Saudi
Para. 5.1.12
Aramco Affairs representative prior to the test.
Copy of the approved pressure testing procedure & the GI-2.102 are
SAES-A-004,
A 17 available at site. Test Personnel are safety trained/experienced.
Para. 5.6.1

B Verification of Actual Test Set-up & SIS Sheet Data:

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 SAEP-1160,
performed. In event of testing accident, Loss Prevention Dept must be Section 8
B1
able to use diagrams & sketches to recreate actual test set-up/conditions. Bullet Item
Note 2: Testing of multiple lines (test pkgs) on 2
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.

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

SAEP-1160,
checked* for accuracy against the test application and is correct.
Section 8
B2 *Note: Human error (test package calcs) is common. Inspectors
Bullet Item
responsible for testing are able to spot gross errors & prevent unsafe
2
testing & overpressurization of systems & components.

C Test Manifold & Appurtanances (Piping, Fittings, Hoses)

Pressure testing manifolds were separately pressure tested to at least SAES-A-004 Para
C1
1.2 times system test pressure. (Manifold Test Report/Cert) 5.5.4

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

G.I.-2.102,
C2 pipe nipples, fittings) exceed system test pressure by 20%.
Para. 5.1.5.5
See Safety Note 1 in Remarks for isolation valves
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 G.I.-2.102,
C3
identified with a unique number (certificate) D) Para. 5.1.2.5
Shows actual arrangement including hose configuration used
Note 1: Manifold permanent marking (unique ID
#, pressure rating) is legible, traceable & certified (Engineering support
docs).

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
G.I.-2.102,
C4 necessary calculations (SIS sheet) and the appropriate visual Inspection
Para. 5.1.5.5
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.

A blow down valve of adequate pressure rating is installed to G.I.-2.102,

C5
depressurize the system safely (easily accessible to operator). Para. 5.1.5.3

Test Manifold piping pressure tested to at least 20 percent above

test pressure of the system under test. (Exception: Final connection
G.I.-2.102,
C6 between test manifold and system under test may be tested to
Section 5.1.5.5
maximum system test pressure only if a higher test pressure is
impractical.)

Paddles or spectacle blinds & other fabricated test items used to

isolate test sections are at least the same code class rating of systems SAES-A-004
C7
under test or are supported by appropriate code calcs. See Remarks, Para. 8.3
Critical Safety Note 2

Page 3 of 8
SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
D Test Relief Valve(s)

Relief valve is located in the system under test and near the test pump
G.I.-2.102,
D1 with Isolation valves on the inlet and outlet of the relief valve sealed open
Para. 5.1.5.1
during the test. (SAEP-1160, Bullet Item # 3)

Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available) are
set to relieve at 5%* above the hydrotest pressure. SAES-A-004 Para
D2
*Note: Test pressures less than 85% of SMYS can have relief valves 5.5.1
set at 10% above test pressure. Verify SIS sheets calcs.

Relief valve(s) are tested, dated, and tagged (as valid) for a period of one SAES-A-004 Para
D3
week for project pressure tests. Stickers are legible & valid. 5.5.1

E Pressure Gages and Recorders

A minimum of two pressure gages are required for test systems, with
accuracy within 5% of one another.
Note 1: When large systems are tested, Inspection personnel will
determine the need for additional gages.
SAES-A-004 Para
E1 Note 2: Elevation changes (hydrostatic head considerations) &
8.1.5.4
hot weather create pressure testing problems with frequent popping of
relief valves. For this reason, gage accuracy within 2% is best.
Note 3: Careful handling of delicate instruments like test gages is
practiced by test crews. No gage damage or mishandling is found.

Pressure gages and pressure recorders are calibrated within (1) month SAES-A-004 Para
E2
prior to test. Stickers applied indicate latest calibration date. 8.1.5.2

G.I.-2.102,
Avoid the following typical examples of poor practices:Testing equipment
Sec.4 &
E3 with the test gauge located at the bottom of the equipment reading the test
SAES-A-004,
pressure,including the head of test water
Para 5.3
All gages have a range such that the test pressure is within 30% to 80% of SAES-A-004 Para
E4
the full range. 8.1.5.3

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

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

surface metal temperatures shall be recorded and compatible with test
methods (including test solution used to detect leaks). SAES-A-004 Para
F1
Note: ASME V, Art 10, Man. App. 1, Table 1-1021 requires surface 5.6.3
metal temp measurements during testing (detailed in procedure). Record
maximum (direct sun) & minimum test temperatures.

Thermocouples are installed to obtain accurate pipe metal temperature

measurements and to determine the acceptance of the pressure test SAES-L-150,
F2
where pressure variations due to test water temperature changes occur, Para. 11.3
such as in cross-country pipelines.

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

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

Page 4 of 8
SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Page 5 of 8
SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12
SAIC NUMBER DATE APPROVED QR NUMBER
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Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 MECH-
Attachment 1 - SAEP-1160 Test Pkg Minimum Requirements

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SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12
SAIC NUMBER DATE APPROVED QR NUMBER
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Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 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
e) visible
Apply water shall be approved
manufacturer removed from the valve
lubricant bodyCortec
plus 10% and seat area. Blow
VpCI-329 (SAPdry with clean compressed
1000173887) added to all air.
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.

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SAUDI ARAMCO ID/PID - REV - 18-May-05 (Standards Cutoff -March 2012) Rev 6 31-Mar-12
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Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-13 MECH-
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 8 of 8