SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Verification of Test Preparation and Test Equipment for Pressure Testing
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

25-May-05

MECH-

CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL

EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER

EQPT CODE

SYSTEM ID.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME

ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO USE ONLY

WORK PERMIT REQUIRED?

ITEM No. A A1 A2

ACCEPTANCE CRITERIA Preparation for Testing Test Pack is available for verification and review. (Refer to SAIC-L-2001). Pre-Test Punchlisting complete and Test Pack Flow Chart signed accordingly. (Refer to SAIC-L-2001). All pre-test punchlist designated as "A" items are cleared. (NOTE: "A"-items are pre-test punchlists required to be completed prior to pressure testing .) Flanges that will not be disturbed after the pressure test are marked/identified and tightened WITH the approved SAIC-L-2014 & SATR-L-2001. Flushing or internal Cleanliness of system is complete. Test Package Flow chart signed-off accordingly. Components which interfere with filling, venting, draining or flushing shall not be installed until after line flushing and pressure testing are completed. These include orifice plates, flow nozzles, sight glasses, venturies, positive displacement and turbine meters and other in-line equipment. Equipment Excluded from Pressure Test The following equipment are excluded from the in-situ pressure testing of the tested system. a) Rotating machinery, such as pumps, turbines and compressors; b) Strainers and filter elements; c) 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; f) Instrument Devices. Temporary supports are installed if they were determined to be required per SAES-L-150. 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.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Best Practice Best Practice

A3

Best Practice

A4

Best Practice SAES-A-004, Para. 7.1.2

A5

A6

SAES-A-004, Para. 7.1.4

A7

SAES-A-004, Para. 7.2

A8

SAES-A-004, Para. 7.5.2 SAES-L-150, Para. 6.4

A9

All joints including welded joints are left exposed for visual leak detection A10 during the strength test. (NOTE: This excludes joints that will be subject to 24-hr recorded test. ) Work permit is obtained for all pressure testing and associated work within restricted areas as covered in G.I. 2.100, Work Permit System. Equipment and appurtenances that are not adequate for test pressures are isolated.

SAES-L-150, Para. 7.3

A11

G.I.-2.102, Para. 5.6 G.I.-2.102, Para. 5.7

A12

Page 1 of 3

SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Verification of Test Preparation and Test Equipment for Pressure Testing
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

25-May-05

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

If isolation valves are used in lieu of blinds, provisions are A13 made to ensure that no overpressuring can occur in equipment that is not being tested, due to possible valve leak. Materials Safety Data Sheets or Chemical Hazard Bulletins are reviewed for all chemicals handled such as corrosion inhibitor, bactericide, chlorine, and oxygen scavenger, and a written procedure to safely handle A14 chemicals during testing, and proper disposal of the chemicals after testing, is approved prior to start of the work. Personal protective equipment shall be utilized as shown on these sheets and bulletins. A15 The test areas are marked and warning signs posted to alert approaching personnel. 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. 5.7

G.I.-2.102, Para. 5.9

G.I.-2.102, Para. 5.11

A16

G.I.-2.102, Para. 5.11

If non-Saudi Aramco facilities will be exposed in a pressure test of Saudi Aramco facilities, the proponent organization of the test shall so inform A17 the Saudi Aramco Affairs representative prior to the test. B B1 Test Piping and temporary appurtenances: Test piping, fittings and hoses are designed or have pressure rating that matched or exceed the system test pressure. Paddle blinds or spectacle blinds used to isolate the test sections are of the same class rating of the system or may be fabricated based on appropriate calculations. Test Manifold The pressure testing manifold was separately pressure tested to at least 1.2 times the system test pressure. Pressure rating or design of test manifold components, ie: isolation valves, pipe nipples, are not less than 20% above the system test pressure. A blow down valve of adequate pressure rating is installed to depressurize the system. An isolation valve of adequate pressure rating is installed to isolate the test piping manifold from the system under test. Test Relief Valve(s) Relief valve(s) of adequate capacity are set to relieve at 5% above the hydrotest pressure. The relief valve(s) are tested, dated, and tagged within one week prior to the pressure testing. Isolation valves installed on the inlet and outlet of the relief valve are sealed open during the test. The relief valve is located in the system under test and near the test pump.

G.I.-2.102, Para. 5.12

G.I.-2.102, Sec.4 SAES-A-004 Para. 7.3

B2 C C1

SAES-A-004 Para 5.5.4 G.I.-2.102, Para. 5.5 G.I.-2.102, Para. 5.5 G.I.-2.102, Para. 5.5

C2

C3

C4 D D1 D2 D3

SAES-A-004 Para 5.5.1 SAES-A-004 Para 5.5.1 G.I.-2.102, Para. 5.5 G.I.-2.102, Para. 5.5

D4

Page 2 of 3

SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Verification of Test Preparation and Test Equipment for Pressure Testing
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

25-May-05

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. E

ACCEPTANCE CRITERIA Pressure Gages and Recorders A minimum of two pressure gages are required for the test system. Their accuracy shall be within 5% of one another. (NOTE: When large systems are tested, Inspection personnel will determine the need for additional gages. ) Pressure gages and pressure recorders are calibrated within one (1) month prior to the test. Stickers shall be applied indicating the latest calibration date. A Test gauge is located at the bottom of the equipment to inable the reading of the test pressure, including the head of test water. All gages have a range such that the test pressure is within 30% to 80% of the full range. Temperature Gages (when required, ie: 24-hr recorded test) 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.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

E1

SAES-A-004 Para 7.1.5

E2

SAES-A-004 Para 7.1.5 G.I.-2.102, Sec.4 SAES-A-004 Para 7.1.5

E3

E4

F1

SAES-L-150, Para. 11.3

REMARKS:

REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 April, 2002) 2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely , (22 July, 2001) 3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003)

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

QC Inspector
Performed Inspection Name, Initials and Date: Work / Rework May Proceed

PID Representative
T&I Witnessed Name, Initials and Date: QC Record Reviewed Work Verified

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

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

Y = YES

N = NO F = FAILED

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