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SAIC-A-2013
WBS / BI / JO NUMBER
1-Dec-06
MECH.
CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL
EQPT CODE
SYSTEM ID.
PLANT NO.
ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL
ITEM No. A A1
ACCEPTANCE CRITERIA General Requirements Pressure Test Procedure is approved and all safety precautions per GI0002.102 & SAES-A-007 (Chemical Handling) have been taken. All in-line valves (if not test isolation) are open*. Note: A fully open valve can leak at stem packing. Items that interfere with filling & Sensitive equipment have been removed from the piping system. System test limits are checked during Inspection walk down Inject oxygen scavenger, biocide and other treatment chemicals continuously at a rate that will provide the specified concentration while filling the system for the hydrostatic test. See Attachment 1 Ensure safe filling of systems with properly proportioned chemical treatments. See Attachment 1 for these details. Filling & pressurization is done upstream of check valves in system. Test fluid enters (shall be drained) at the lowest point in the system. All vents are open during filling. Minimize Trapped air. See Attachment 1 (Hydrotest Filling & Venting Practices) Quality Manager & Inspection Action Required for Efficiency Remove air during filling by the following measures: A) Design/Plan Tests. Provide high point vents. B) Mechanically (Use scrapers as needed to remove air). C) Follow Attachment 1 regarding Efficiency Note: Venting may be accomplished by vent valves or blind flanges with properly attached test implements (welded couplings, etc) that are located at the highest point in the flange to minimize trapped air. After venting, valves used for venting are placed in the partially open position and plugged or blinded as applicable. Procedure requirements are followed step by step: A) Test Medium is applied as per approved test package B) Test sequence is controlled. Maximum test pressure is per approved test package SIS sheet & Pressure Test Report Form. C) Pressure rise is staged (Adequate* hold time between stages) D) Inspection & Test Crew follow safety responsibilities during test E) Safeguards (clearance, barricade, signs, permits) are in effect *10-minute equalization time is an approximate value used in the GI. Preliminary check for leaks at 50% of the strength test pressure was performed. Test crews were efficient in filling practices. See Attachment 1 regarding Testing Efficiency Temperature of the water during hydrostatic testing was maintained well above 60 degrees F (16 C) due to Brittle Fracture consideration A 17C Value is listed in 32-SAMSS-004 (tanks). This equals 62.6 F. Note:This should never be a problem in Saudi. However, air temps can drop to below 10 C & water temperatures will drop as well. Water temps for Pipeline & Plant Piping testing should also follow this minimum reqmt. Document the "actual" test temps when low. Note: On the other end, solar heating can create problems when testing small diameter piping sections, with difficulty in achieving successful test results. However, when efficient filling practices are utilized & tests are well coordinated, this is NEVER a problem. See Attachment 2.
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
A2
A3
SAES-A-007 Section 8
A4
A5
A6
A7
A8
A9
Page 1 of 7
SAIC-A-2013
WBS / BI / JO NUMBER
1-Dec-06
MECH.
CONTRACTOR / SUBCONTRACTOR
ACCEPTANCE CRITERIA
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
ATTACHMENTS: Attachment 1 - SAES-A-007 Hydrostatic Test Water Preparation, & Hydrotest Filling & Venting Practices (Efficiency) Attachment 2 - Efficient Practice For Acceptance of Pressure Tests REFERENCE DOCUMENTS: 1. SA General Instruction Manual GI-002.102, Pressure Testing Safely, (July 22, 2001) 2. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 3. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (5 October, 2005) 4. 32-SAMSS-004, Manufacture of Pressure Vessels, (30 March, 2005)
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
Y = YES
N = NO F = FAILED
Page 2 of 7
SAIC-A-2013
1-Dec-06
MECH.
10 Safety
10.1 Follow procedures outlined in the Chemical Hazard Bulletins & Hazardous Materials Communications Program (HAZCOM) labeling provided by the Environmental Compliance Division, Environmental Protection Department for handling, storage, and mixing of the chemicals to be used for hydrostatic test water treatment. 10.2 Provide an effective eye wash station/emergency shower per SAES-B-069 at mixing site of chemicals. 10.3 Hydrotests shall avoid the use of biocide during hydrotest itself unless absolutely essential. Lay-up water may be treated with biocide as necessary. 10.4 See paragraph 4.2.6 concerning water. SEE WARNINGS BELOW!!! 10.5 Hydrotest procedures may involve the displacement of hydrocarbon by fluids, the displacement of air, and the use of nitrogen. 10.5.1 Procedures ensure that explosive mixtures of air & gas cannot occur. For example, use of a single scraper in a pipeline is not sufficient to prevent a dangerous mix occurring between sweet gas and air. Common practice is to use a train of scrapers with at least 2 batches of nitrogen separating air and gas. 10.5.2 Methanol is a toxic & inflammable chemical & may be used only with adequate safety precautions. 10.5.3 Caution (nitrogen). Not toxic, yet exclusion of breathable air in confined spaces can = suffocation.
Page 3 of 7
SAIC-A-2013
1-Dec-06
MECH.
Page 4 of 7
SAIC-A-2013
WBS / BI / JO NUMBER
1-Dec-06
MECH.
CONTRACTOR / SUBCONTRACTOR
ACCEPTANCE CRITERIA
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
ATTACHMENTS: Attachment 1 - SAES-A-007 Hydrostatic Test Water Preparation, & Hydrotest Filling & Venting Practices (Efficiency) Attachment 2 - Efficient Practice For Acceptance of Pressure Tests REFERENCE DOCUMENTS: 1. SA General Instruction Manual GI-002.102, Pressure Testing Safely, (July 22, 2001) 2. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 3. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (5 October, 2005) 4. 32-SAMSS-004, Manufacture of Pressure Vessels, (30 March, 2005)
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
Y = YES
N = NO F = FAILED
Page 5 of 7
SAIC-A-2013
1-Dec-06
MECH.
10 Safety
10.1 Follow procedures outlined in the Chemical Hazard Bulletins & Hazardous Materials Communications Program (HAZCOM) labeling provided by the Environmental Compliance Division, Environmental Protection Department for handling, storage, and mixing of the chemicals to be used for hydrostatic test water treatment. 10.2 Provide an effective eye wash station/emergency shower per SAES-B-069 at mixing site of chemicals. 10.3 Hydrotests shall avoid the use of biocide during hydrotest itself unless absolutely essential. Lay-up water may be treated with biocide as necessary. 10.4 See paragraph 4.2.6 concerning water. SEE WARNINGS BELOW!!! 10.5 Hydrotest procedures may involve the displacement of hydrocarbon by fluids, the displacement of air, and the use of nitrogen. 10.5.1 Procedures ensure that explosive mixtures of air & gas cannot occur. For example, use of a single scraper in a pipeline is not sufficient to prevent a dangerous mix occurring between sweet gas and air. Common practice is to use a train of scrapers with at least 2 batches of nitrogen separating air and gas. 10.5.2 Methanol is a toxic & inflammable chemical & may be used only with adequate safety precautions. 10.5.3 Caution (nitrogen). Not toxic, yet exclusion of breathable air in confined spaces can = suffocation.
Page 6 of 7
SAIC-A-2013
1-Dec-06
MECH.
Page 7 of 7