SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Pressurization for Bubble Leak Test (Using Air, Inert Gas)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2023
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

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

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

General Requirements for Systems with Air or Inert Gas ... USE SATR-A-2010 Note 1: (Bubble Leak Test at 5-10 psi in association with Pneumatic Strength or Service Test in lieu of Strength Test) Note 2: Use this checklist in conjunction with SAIC-A-2020, SAIC-A-2021 & approved ASME V Procedure (SAIC-A-2005) Approved Bubble Test Procedure & Pressure Test Package is available at site before testing commences. (GI-2.102 also available) Note: Test procedures are understood and followed by trained test crews & Inspection personnel in attendance. Thorough visual inspection of equipment/system to be tested has been performed including all piping components included in the test limits as shown in the Test diagram and approved P&ID. Note: Designated "A" items in Pre-Test Punchlist are corrected. Construction completeness has been accepted. Adequate thread engagement (maximum two full threads visible rule) & final flange installation has been accepted in systems under test. SAIC-L-2015 & SAIC-W-2037 has been completed for system Due consideration is given to available lighting for examination and surface temperatures of metal during testing. During hot weather, leak tests are early in the day (morning). Tests done at night have adequate artificial lighting for inspectors performing visual exams. Pressure gages & recorders are currently calibrated before tests. A minimum of two pressure gages are required for the test system. One pressure gage shall be on the test pump and the other(s) on the test system. Their accuracy shall be within 5% of one another. During the application of the test pressure, all in-line valves if not used as test isolation valves are in an open position. All flange joints are double-layer taped 360 degrees with a 4-6 mm hole punched at the high point for detection of leaks. (Procedure). Note 1: Avoid Gray duct tape use on SS systems (High Chlorides) Note 2: A Ball Point Pen is used to punch a singular hole in tape. Proper test medium (inert gas or steam) is used as specified in the approved leak test procedure. Means of control for access to site is in place (Safety Precautions) When performed with a pneumatic test, bubble leak tests shall be performed & evaluated AFTER Pneumatic Strength tests by safely lowering systems under test pressure to a pressure of 10 psi. Note: Recommended also is the practice of checking for leaks "on the way up" during pressurization to 50 % of pneumatic strength test pressures. Reason: Leaks at 50% of test pressure will still be found at 10 psi. This is a cost savings (time spent) due to rework. When performed with a service test, bubble leak tests shall be performed at 5-10 psi PRIOR TO achieving Service Test Pressures. SAES-A-004, Para. 7.1.1

A1

A2

G.I.-2.102, Para. 5.1

A3

SAES-A-004, Para. 5.6.1 SAES-A-004, Para. 7.1.5 SAES-A-004, Para. 7.1.5 c SAES-A-004, Para 8.1.3 SAES-A-004, Para. 5.6.1

A4

A5

A6

A7

A8

G.I.-2.102, Para. 5.3 G.I.-2.102, Para. 5.11

A9

A10

SAES-A-004, Para. 5.6.1

A11

SAES-A-004, Para. 5.6.1

Page 1 of 3

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Pressurization for Bubble Leak Test (Using Air, Inert Gas)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2023
WBS / BI / JO NUMBER

1-Dec-06

MECH.

CONTRACTOR / SUBCONTRACTOR

ITEM No. A11 B B1 B2 B3

ACCEPTANCE CRITERIA

REFERENCE SAIC-A-2016, as applicable

PASS

FAIL

N/A

RE-INSP DATE

Utilize SAIC-A-2021 Conditions for test are acceptable.

PERFORMANCE OF TEST (ASME V PROCEDURE GUIDELINES) Achieve test pressure of 5 - 10 psi on the system under test. Apply removable tape to test gauge & match mark needle with a pen. Wait a minimum of 15 minutes at test pressure of 10 psi (soak time). System under test is ready for leakage evaluation with application of an approved bubble test solution following procedure. Snoop is a SA Approved Solution (SAIC-A-2004). Evaluation of Test Results & Repairs Leaks are identified (per Procedure) and joints that fail test are identified for remedial action (repair). SAIC-L-2015*, SAIC-W-2037 Disposition of Leakage shall be addressed in Procedure. Flange Leaks are addressed per SAEP-351 requirements. Defective piping sections or components are replaced. *Threaded joint repairs per Procedure (SAIC-A-2015, Att. 7) No leaks are identified, system is accepted. Perform Reinstatement. Reinstatement per Procedure (SAIC-A-2006) is req'd. Depressurization Depressurize systems before stopping or repairing leaks.

SAES-A-004, Para. 5.6.1 SAES-A-004, Para. 5.6.1 SAES-A-004, Para. 5.6.1 SAES-A-004, Para. 5.6.1

B4 C

C1

Per Procedure (Gap Control)

C2 D D1

SAEP-1160, Section 8

G.I.-2.102, Para. 5.17

REMARKS:

REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 2. G.I.-2-102, Pressure Testing Safely, (22 July, 2002)

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

Page 2 of 3

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Inspect Threaded Joint Engagement (Gap Control)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-L-2015
WBS / BI / JO NUMBER

1-Dec-06

PIPE-

CONTRACTOR / SUBCONTRACTOR

ATTACHMENT 7 - REPAIR METHODS FOR THREADS & THREADED JOINTS

PROCEDURE SHALL RELATE EXACT METHODS TO BE USED TO PROVIDE DETAILED ADEQUATE WORK INSTRUCTION WHEN LEAKS ARE FOUND IN THREADED JOINTS DURING TESTING* (*SERVICE/PRESSURE). INSTRUCTION WHEN RECEIVING INSPECTION EVALUATES THREADING SAMPLES (REPAIRS REQUIRED)

GALVANIZED PIPING THREADS

1. Threaded Joint Repairs (Galvanized Piping) are covered in an approved procedure and meet SA requirements: A) Schedule 40 galvanized piping in Utility Services is never seal welded to stop leaks (Prohibited): WPS does not cover thickness range (1mm remaining wall exists below threads for 1 sch 40 galvanized piping) WPS does not cover welding on zinc. Zinc cannot be completely removed for welding without damage to thin piping Zinc is damaged internally and cannot be repaired, affecting corrosion allowance (H-standards, SAES-L-132/133) CSD will not approve WPS for seal welding Sch 40 galvanized B) Acceptable methods of leak repairs for Schedule 40 threaded galvanized piping are as follows: Threaded joints are tightened until leakage stops where wrench tightening is possible Threaded joints are disengaged, cleaned, inspected, replaced/reinstalled with code threads properly engaged Lines are cut. Install unions and new sections as required CLEAN, RETAP, RECHASE THREADS AFTER INADEQUATE ENGAGEMENT BEFORE JOINTS ARE FAILED. RECEIVING INSPECTION SHALL EVALUATE A SAMPLE OF GALVANIZED THREADING (PROACTIVE) Note: Galvanized piping retapped & chased at site receives a coating of zinc-rich primer after rework. (APCS-1C is acceptable) per ASME B1.20.1 and preparation as follows: A) Adequately dry (air) exposed steel surfaces before priming B) Apply coating of zinc-rich primer per SAES-H-001, Table 5 (H) C) Cover, protect and store threaded ends same as Carbon Steel Lines shall be leak tested as early as possible to assure tight joints. This is a preliminary leak test at 10 psi PROCEDURE SHALL RELATE EXACT METHODS TO BE USED TO PROVIDE DETAILED ADEQUATE WORK INSTRUCTION WHEN LEAKS ARE FOUND IN THREADED JOINTS DURING TESTING

CS, SS, ALLOY PIPING THREADS

2. Threaded Joint Repairs (CS, SS & Other metallurgies) are as follows: A) WPS for seal welding is followed (thread compound is removed) & SA Approval is attained (Procedure) B) Seal welding is not allowed Threaded joints are tightened until leakage stops where wrench tightening is possible Threaded joints are disengaged, cleaned, inspected, replaced/reinstalled with code threads properly engaged

OTHER THREADED JOINT REPAIR CONSIDERATIONS

3. Procedure considers Repairs for the following considerations and details corrective measures: A) Considers mechanical damage & provides corrective action measures. B) Considers Ovality (gross joint distortion) after assembly due to poor workmanship & provides corrective action. C) Considers incorrect gap repair measures (inadequate thread engagement using 2-visible thread rule) . D) Considers thread engagement checks by use of gauges or fittings to check hand tight engagement.

E) Considers workmanship & inappropriate use of wrenches: Prevent deep gouges in galvanized piping that violate minimum wall thickness. Prevent carbon steel contamination to SS & other metallurgies. Procedure states: Strap wrench or protective wrapping shall be used in a good workmanship effort to prevent damage & CS contamination on threaded piping
CLEAN, RETAP, RECHASE THREADS AFTER INADEQUATE HANDTIGHT ENGAGEMENT BEFORE REJECTION.

ENSURE APPLICATIONS FOR ANY THREAD REPAIRS ARE COVERED BY THE REPAIR PORTION OF THIS PROCEDURE
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