SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
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 General Requirements (Complete SATR-A-2007, listed as Attachment 5 & use SATR-A-2011 & SATR-A-6133)

Post Test Reinstatement Procedure & Checklist is required to

be developed in accordance with & as part of pressure testing.
This is a pressure testing procedure & test package component to be
developed during package creation as based on workscope & specific
SAEP-1160,
A1 "system" requirements.
Section 8
Comment: A standard post-test checklist does not
provide a procedure for reinstatement. A detailed procedure to give
clear field direction along with a checklist for this activity shall be
submitted before the start of work.

Inspection strategies & plans shall be prepared and agreed on prior to

SAES-L-350,
A2 commencing of fabrication and erection. This is in common with
Para. 17.2
Pipelines. Pipelines simply follow their reinstatement procedure.

Specifically, Procedure shall detail PLAN or STRATEGY to reach

"SYSTEM" COMPLETION (Quality Certification) as efficiently as possible
while accomplishing critical goals of:
A) Effective Water Removal,
Disposal & System Lay-Up (Post Test) No
test fluid shall remain in low spots. Specifically, valve cavities. SAES-L-350,
B) Test Vents and Drains (plugged, seal welded & PT'd) Para. 17.2 &
A3 C) Removal & reconnection of components
All temporary items installed for SAES-A-004,
testing (e.g., manifolds, valves, Section 10
blinds, spacers, supports) shall be removed. Valves Installed. Items that
were removed from testing shall be reinstalled. Items, such as instrument
air tubing, check valve discs reconnected (witnessed). Valve line-up &
gasket installations meet specifications.

Effective Corrosion Control & Preservation Measures

Inspection Coverage and
Responsibilities (Package Clearance) SAES-L-350,
A4
Clearly detailed provisions for Retesting after reinstatement Evaluations Para. 17.2
by Inspection. Construction related provisions.

Page 1 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

B SAIC-A-2010 Checklist (Reinstatement Procedure & Checklist item required when bold.)

SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS (See E-Library, Folder 25)

All joints including welded shall be left exposed for visual leak detection
during the strength test. External coating and priming of such joints are SAES-L-150,
B1 not allowed unless approved by the Manager of Inspection Department Para. 7.3
and the proponent Organization representative. The pipe itself can be
externally primed and coated to a final coat.

The assembly of bolted flange joints shall be in accordance with SAEP- SAES-L-450,
B2
351. Para. 9.4

Drains: Excluding submarine and buried pipelines, drains shall be SAES-L-150,

B3
provided at all low points of the piping system. Para. 6.2

Vents and drain valves, both temporary and permanent, conforms with SAES-L-105,
B4
the piping class or rating. ( Refer SAES-L-108) Para. 5.9

Supports: For above ground installation, the piping system shall be

analyzed to foresee whether temporary supports are required during
hydrostatic testing to limit the sustained longitudinal stresses to SAES-L-150,
B5
acceptable limits by the code. If temporary supports are found to be Para. 6.3
needed and more economical than permanent supports, this should be
highlighted in the hydrotesting procedure.

Expansion joints and spring hangers or spring supports shall be provided

SAES-L-150,
B6 with temporary restraints where needed to prevent excessive travel or
Para. 6.4
deformation under the test loads.

Arc strikes, gouges, and other indications of careless workmanship (such

SAES-W-011,
as surface porosity, uneven weld profiles, and undercut) shall be
B7 Para. 11.6 and
removed by grinding and inspected by magnetic particle or liquid
11.9
penetrant method.

SAES-W-011,
Temporary welded attachments to the pipe were ground off and
B8 Para. 11.7 and
inspected by magnetic particle or liquid penetrant method
11.9

All threaded joints and faying surfaces shall be seal welded by a SAES-W-011,
B9
continuous fillet weld (required weep holes shall be left unwelded). Para. 11.15.1

If requested by the proponent, all new valves designated for isolation

SAES-L-108,
B10 service (as specified by the Proponent) shall be subjected to a high
Section 4.7.2
pressure hydrostatic seat test prior to installation in the line.

Filling and pressurizing shall be done on the upstream side of check

valves in the system. The test fluid shall be injected at the lowest point in
SAES-A-004,
B11 the system to minimize entrapped air. When filling at the lowest point is
Para. 9.1.1
not practical, the Inspection Department/ Operations Inspection
Engineering Unit shall be consulted. All vents shall be open during filling.

Page 2 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

No one shall approach the test area for a minimum of 10 minutes after
the test pressure is reached and before commencement of inspection of
the system, the isolation valve between the temporary test SAES-A-004,
B12
manifold/piping and the piping/equipment under pressure test shall be Para. 9.1.2
closed and the test pump disconnected. The isolation valve downstream
of the manifold shall be opened after the pump is disconnected.

During the application of the test pressure, all in-line valves if not used as SAES-A-004,
B13
test isolation valves shall be in a partially open position. Para. 9.1.3

SAES-A-004,
B14 Vents shall be provided at all high points in the tested system as needed.
Para 8.4.1

Excluding scrapable, submarine and buried pipelines, drains shall be

SAES-A-004,
B15 provided at all low points in the system and immediately above check
Para 8.4.2
valves in vertical lines.

Unless the check valve has a by-pass valve, the disc of the check valve
SAES-A-004,
B16 shall be removed, and securely attached to the outside of the check
Para 8.4.3
valve prior to the pressure test.

Flanged connections shall be avoided when butt-welded joints can be

used in services and locations where leaks are likely to occur (e.g., cyclic
or vibration services), or will cause serious hazard (e.g., potentially toxic
material), or are difficult to control, such as the following:
a) Steam in ASME class 900 pressure rating SAES-L-110,
B17
b) In the fully restrained portion of cross-country pipelines and in Para. 8.1
underwater pipelines
c) In locations where the piping will be subjected to large bending or
other external loads
d) On buried piping system

Flanged connections with long exposed bolts for sandwiched

components, other than standard spectacle plates and blinds, shall not
SAES-L-110,
B18 be used in fire hazardous areas unless the bolting is protected by a fire
Para. 8.2
resistant shield such as illustrated on Standard Drawing AC-036404 or
equivalent method. (Ref. SAES-B-006).

Soft seated valves and control valves shall not be installed until after the SAES-A-004,
B19
lines have been thoroughly flushed. Para. 8.1.3

Before employing the pressure testing manifold in the actual system

pressure test, it shall be separately pressure tested to at least 1.2 times SAES-A-004,
B20
the system test pressure but not less than the discharge pressure of the Para. 5.5.4
pump used for the pressure testing.

Buried pipeline are adequately bermed or covered to anchor the line SAES-L-450
B21
during pressure test. Appendix C

All gauges and recorders shall be calibrated prior to use. The calibration
interval shall not exceed one (1) month prior to the test date and SAES-A-004,
B22 calibration certificates shall be made available to Inspection personnel Para. 8.1.5.1 and
prior to commencement of the pressure test. Stickers shall be applied 8.1.5.2
indicating the latest calibration date.

All gauges shall have a range such that the test pressure is within 30 to SAES-A-004,
B23
80% of the full range. Para. 8.1.5.3

Page 3 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

A minimum of two pressure gauges are required for the test system. One
SAES-A-004,
B24 pressure gage shall be on the test manifold and the other(s) on the test
Para. 8.1.5.4
system. Their accuracy shall be within 5% of one another.

When large systems are tested, Inspection personnel will determine the SAES-A-004,
B25
need for additional gauges. Para. 8.1.5.5
Pressure and temperature recording gauges shall be used for all buried SAES-A-004,
B26
piping systems on plot and per SAES-L-150 for pipelines. Para. 8.1.5.6
Blind flanges, Paddle or spectacle blinds shall be used to isolate test SAES-A-004,
B27
sections. Para. 8.3
A bleed valve readily accessible is provided in case immediate SAES-A-004,
B28
depressurization is required. Para. 5.5.2

Draining of Test Fluid- Release of pressure and draining shall be done on

the downstream side of check valves. All vents shall be opened before SAES-A-004,
B29
draining to facilitate drainage and to prevent formation of a vacuum. No Para. 10.1
test fluid shall remain in low spots.

Disposal of Test Fluid-The test fluid shall be disposed in accordance with SAES-A-004,
B30
SAEP-327 or as directed by the Owner. Para. 10.2

Test Vents and Drains-Vents and drains used only for the pressure test SAES-A-004,
B31
shall be plugged, seal welded and penetrant tested. Para. 10.3

Removal and Reconnection of Components- All temporary items installed

for testing purposes (e.g., manifolds, valves, blinds, spacers, supports)
shall be removed. Items that were removed from testing shall be
reinstalled. Items, such as instrument air tubing, check valve discs which SAES-A-004,
B32
were disconnected before testing shall be reconnected. Isolation valves Para. 10.4
closed for the test purposes and that are required to be in the open
position for process reasons shall be opened. If the valve cavity has a
drain, the cavity shall be drained.

REMARKS:

REFERENCE DOCUMENTS:

1. SAES-A-004, General Requirements for Pressure Testing, (30 January 2011)

2. SAES-L-105, Piping Material Specifications, (8 August, 2009)
3. SAES-L-108, Selection of Valves, (11 OCT, 2010)
4. SAES-L-110, Limitations on Pipe Joints and Components, (5 January, 2011)
5. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (25 April 2010)
6. SAES-L-350, Construction of Plant Piping, (22 April 2009)
7. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (12 July, 2010)
8. SAES-W-011, Welding Requirements for On-Plot Piping, (4 October, 2009)
9. SAEP-1160 , Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects (10 July 2011)
10. SAEP-351, Bolted Flange Joints Assembly (7 November 2006)

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:

Page 4 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Page 5 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-

Attachment 1 -- SAEP-1160 Section 8 (Test Pkg Minimum Content)

Page 6 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-

Attachment 2 -- NEMA TC 2 (Type EPC-40-PVC)

Attachment 2 -- TEST PACKAGE FLOW CHART

Test Package (or Test System) No

Test Pack
Preparation Engineering Contractor QC

Pre-Test
Punch (NOTE: Use form SATR-A-2007)
Construction Contractor QC
Listing

Clear 'A'
Items Construction Contractor QC

S. Aramco
Pre-Test
Punch
SAPMT PID Proponent
Listing (By Request)

Clear
S. Aramco
Construction Contractor QC SAPMT PID
'A' Items

Flushing &
Cleanliness Construction Contractor QC SAPMT PID Proponent
(By
Request)

Pressure
Testing Construction Contractor QC SAPMT PID Proponent

System
Lay-Up Construction Contractor QC SAPMT PID Proponent
(By
Request)
Reinstate
System

Final
Insp
(Contractor) Page 7 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Reinstate
Review
SystemProcedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
Final Construction Contractor QC SAPMT
Insp
(Contractor)

S. Aramco
Final Insp for
MCC SAPMT PID Proponent

Page 8 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
Attachment - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)
SYSTEM TEST PRESS TEST CONSIDERATIONS & NOTES
&
Process DURATION
As Calculated* Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test
30 mins (min) required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu of
Piping pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process requests
per Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.

*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of new
constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below.

Lube & Seal Oil See Notes *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig,
30 mins (min) whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely
Systems cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints
Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged and
threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the joints (check
low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.

Underground As Calculated A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum of 2 hrs B) If
See Notes justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd.
Process Piping
Flare Lines See Notes Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested
30 mins pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & (min)
above)
Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less than 24
inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5 psig in lieu of a high
pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc when requested by Company.
Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.

Vacuum Piping See Notes Tested to 1.5 times the differential external pressure, but not less than 15 psig.
30 mins
(min)
Air & Inert Gas SERVICE TEST & Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joints
(150 psig Soap Bubble Test
30 mins
are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver
Service tests and final gasket installation.
max) (min)
LP Steam SERVICE TEST Coordinate with system Service tests and construction completion.
30 mins (min)
(60 psig max)
Weld-Plus-Ends Soap Bubble Leak Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus
Test at 5-10 psig between the gasket and the seal weld. It shall be examined for leaks using a soap solution.

Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the
30 mins (min) Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined and
Piping taken into consideration when calculating the test pressure. In case of flanged tie-in connections, a
Incl. Tie-Ins flange tester is utilized to conduct hydrostatic testing of flange butt weld.

RETESTING See Notes Systems that already passed a successful pressure test require RETEST IF subjected to new welding
activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
REQMTS
Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE RETEST
UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).

REPAIR See Notes Every existing plant piping & pipeline, after repairs or alterations have been made that affect the
integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test pressure
EXISTING shall be in accordance with the requirements of the applicable code.
PIPING
Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc
Open-Ended EXEMPT, Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
VISUAL EXAM atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc
Piping
Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined.
Instrument As Calculated* Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
30 mins (min) pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or
Impulse Lines process equipment to which it is connected. Test duration shall not be less than 30 minutes.

Note: Instrumentation that could be damaged due to the test shall be disconnected. When pneumatic test is not practical (pressure greater than 1000
psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
Internally FBE As Calculated* For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not exceed
30 mins (min) 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System
Coated Lines
Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.

Sampling Lines See Note Test as an integral part with the piping or equipment to which it is connected.

Vessel & Tank See Note Test separately (separate package) as required. Exemptions include sight glasses &
other instruments. Strength or Service test associated piping based on service
Trim
(Piping)
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test
Skid-Mounted EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct misalignment,
Piping (Vendor) (exceptions noted) physical damage or any modifications in-situ, pressure test the affected spools.

FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042)
Test Location See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Field Testing of See Note All new valves designated for isolation service (as specified by the Proponent) shall be
subjected to high pressure hydrostatic seat test prior to installation in line.
New Valves
Exception See Note Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!

Exemption See Note Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt
Procedure See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to
those that the valves were originally purchased to. All resilient (soft) seated isolation
(Checklist
Item D4)
valves shall have zero leakage. See SAIC-L-2042
Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a unique
ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique ID &
corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg & Database (Piping
System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (internal
visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions & follow-up preservation reqmts) &
segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.

SPECIFIC TESTING REQUIREMENT SUMMARY (ALL SA APPLICATIONS PER SAES-L-150, Section 6)

6.1 Plant Piping - Pressure testing of On-Plot Plant Piping shall be per SAES-L-150. See Section D of this Checklist.
6.2 Cross-Country Pipelines - Pressure testing of cross country pipelines shall be per SAES-L-150. See Section C of this Checklist.
6.3 Pressure Vessels - Hydrostatic testing for new vessels (shop or field fab) shall be conducted as follows:
ASME Section VIII, D1 to SAMSS-004, Para 16.3.8.1. & ASME Section VIII, D2 to 32-SAMSS-004, Para 16.3.8.2
Hydrostatic testing for existing vessels shall be conducted per SAES-D-008, Paragraph 10.1.
Pneumatic test as approved by Insp Dept Mgr (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2)
6.4 Heat Transfer Equipment - Hydrostatic tests for existing equipment shall be per SAES-D-008.
For pneumatic testing, refer to same as above for Vessels (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2)
Boilers receiving Hydrostatic test (new, field fabricated boilers) shall be in accordance with 32-SAMSS-021.
Boiler pressure test After Repair or Alteration, refer to SAES-D-008 & National Board Insp Code, NB-23.
Boiler Hydrostatic test during T&Is shall be per test pressure as specified on boiler's safety instruction sheet.
Heater Tube (coil) Assy Hydrostatic test for new, field fabricated heater tube assembly shall be per 32-SAMSS-029.
Heat Exchanger Tube bundles removed from X-chgr (maintenance) get in-situ shell side test per SAES-D-108 prior to return to service
Fin Fan X-chgr is strength tested (as stamped) in-situ prior to final acceptance (new project), & whenever transported.
6.5 Tanks - For new, field fabricated tanks, & existing tanks, hydrostatic testing shall be per 32-SAMSS-006 for large, low pressure welded tanks;
or 32-SAMSS-005 for atmospheric steel tank, as applicable.
6.6 Fire Protection Systems - Pressure test new & existing fire protection systems (SAES-B-017, GI-1781.001).
6.7 Refrigerant Piping Systems - Refrigerant piping serving building air conditioning systems shall be tested according to the requirements of SAES-
K-001 and the Uniform Mechanical Code (UMC), Section 1520.
6.8 Potable Water Systems - Potable water piping inside buildings shall be tested per the reqmts of Uniform Plumbing Code (UPC). Exceptions to
UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS
Potable water piping outside of buildings shall be tested per the requirements of SAES-S-040 (SAES-S-070, Section 18).

6.9 Utility Piping Systems - Utility systems, including irrigation piping & water distribution mains, shall be tested per SAES-S-070, Sect 18
6.10 Industrial Drainage and Sewers - Industrial drainage and sewers shall be tested per SAES-S-020 (SAES-070, Section 18).
6.11 Sanitary Sewers - Sanitary sewer systems within buildings shall be tested per reqmts of the Uniform Plumbing Code (UPC). Exceptions to
UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS
Sanitary sewer lines outside of buildings shall be tested in accordance with SAES-S-070 Section 18.

6.12 Storm Water Drainage Systems - Test per SAES-S-030 (SAES-S-070, Section 18) Note: Only OWS portions are tested.
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Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
6.13 Miscellaneous Building Services Piping - Steam & condensate piping outside the jurisdiction of ASME B31.3, heating & cooling water piping,
vacuum & compressed air system piping for building services shall be tested per ASME B31.9, Building Services Piping.
6.14 Gas Cylinders - Gas cylinders shall be tested per Saudi Aramco Bottled Gas Manual. (Application - New Labs, etc)
6.15 Valves - Valves shall be tested in accordance with SAES-L-108, Section 4.7
6.16 Non Metallic Piping - Such as RTR, Thermoplastic, PVC/UPVC & CPVC shall be tested per SAES-S-070, Section 18.

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-

Attachment 4 - SPEC CHECK INSTRUCTIONS

1) Test Package Review Tool & Special Process Clearance Verification BEFORE Hydrotest.
a. Use Spec-Check along with SAIC-A-2003 (Checklist for Hydrotest Package Review) & this checklist.
b. Check test package Bill of materials against piping line class requirements (See sample Spec Check)
c. Check NDT requirements in SPEC-CHECK against NDT enclosed in given test packages. Check for correct NDT
looking for omission
extent specified and of
correct NDT methods. Check NDT reports and compare RT field markings to the test reports.
d. Check RT reports closely for repairs (repair shots, penalties) & field verify the markings exist on the correct joint.
Note: If discrepancies exist, simply review the film and follow NDT checklists for RT (Clear direction exists here).
e. Shop/Field Weld NDT requirements vary and need to closely checked for omission of work. (10% shop, 100% fld)
f. Check PWHT reports against material spec requirements (service, thickness, etc). Verify visually PWHT was done
g. Check BHT reports against spec requirements (sweet & sour services). Verify roundness of Brinnell indentation.
h. PMI OK markings exist on those joints PMI examined. Verify markings to correct joint.
i. Check color codings of materials to assure correctly specified material was used in piping systems.
2) Check field installations (Pre-Hydro Walkdown, Surveillances) for following special processes:
a. Gasket Installation HOLD POINT FOR CONTRACTOR - Visual before installation, Color code Table
CRITICAL: COLOR CODES EXIST FOR ALL GASKETS (TABLE COVERS ALL GASKETS IN ALL LINE CLASSES)
b. Bolting Installation & Torque (Bolts, Nuts, Lubricants, Friction Factors, See Torque Tables)
c. Valve Installations (Check Valves installed against SAES-L-105 Spec Table Attached)
d. Piping specs and piping schedules cab be included
e. Check Spectacle plates, blinds, spacers, Jack screws, etc for SPECIFIC SASD DRAWING conformance.
f. Check miscellaneous material elements (Class & pressure ratings for weld bosses, fittings) & Limitations (L-110)
g. Check WPS and any special instructions needed per welding (invaluable tool for Control)
3) Perform FOCUSED ASSESSMENTS with both CHECKLISTS & SPEC-CHECK
4) Perform Focused Assessments with Spec-Check alone on all specified Materials
5) Perform Focused Assessments with Spec-Check alone on Special Construction Processes.
6) Perform Post-Hydro Checks in the field (Reinstatement, FEIL, Pre-Commissioning, Commissioning)
a. During Reinstatement, Use Spec-Check along with SAIC-A-2010 (Checklist for Hydrotest Reinstatement) to
ensure correct installation (Bolting, valves, etc)
b. During FEIL walkdowns, use Spec-Check during accumulation of Field Exception Items List (FEIL)
c. During Final walkdowns, use Spec-Check one last time (Pre-Commissioning, Commissioning)
7) Add notes for: WPS Review/Compilation after Review of Line Class Tables, Valve Spec codes, flanges,
special walk down notes, supports, etc by using a numerical code and hand written notes on back!
SPEC-CHECK can be modified for any item. Ensure the best quality on your project! Check all specs
Test Package Review Notes
1. Check status sheet for signoffs.
2. Check Index against contents
3. Pressure Test Data Sheet
Check drawing numbers against actual enclosed
Check excluded equipment & especially if there are any P&ID notes
Check pressure test value proposed to assure limiting factor is correct (usually a flange)
4. Do a Weld Tracker NDT report review (detailed)
Compare completed Special Process reports (RT, MT, PT, PWHT, BHT, PMI, etc)
Compare against list of outstanding NDT (Backlog of Penalty & Repairs)
5. Review P&IDs and isometrics against spec check for line class required materials (drawings often are in error)
Note: Make note on cover in Punch list Accepted by PID Field verify against Spec/B.O.M
This is especially critical for Sour Service & Special Service lines.
Note: Ensure orifice flange reports are included & any NDT specified
6. Check hydrotest diagram
Manifold arrangement sketches must show all elements, & manifold construction/insp must be per SAIC-A-2009
Caution: Ensure test pressures do not exceed manifold element ratings (Valves are next size up for systems tested)
Example 1: Class 300 # systems(1125 psi) would utilize a Class 600 Isolation valves in test manifolds at minimum.
Example 2: A manifold with 800# gate valves will not be used in testing 600# systems (2250 psig)

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
Reason: You are testing against the valve seat (closed position) & this is rated for 1.1 times test pressure, not 1.5.
See Next Page for Spec Awareness (Basis for Spec Check on Projects)
SPEC AWARENESS
PIDs ATTENTION TO SPECS & SPEC-Check
(Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects:
Initial Review of SPECS
1. Carefully recheck Contractor Piping Specs (Line Class Summary & Tables) as early as possible during or just
after Design is complete (as soon as they are issued and available).
2. This is done by checking Contractors specs against Line Class Material requirements listed in SAES-L-105. Give
special attention to critical systems & systems above 300#.
3. Average large projects can have as many as 50 different piping specs & details can be very hard to pick up in the
field. Pipelines have fewer specs and are easier to manage. THIS INCLUDES THE MAZE OF GASKETS!!!
4. Time taken for early review only takes an experienced plant inspector 2 days of review. Findings (often human
error) can be critical. Help prevent unplanned shutdowns on your projects & find substandard material specs before
they are installed or before they enter service.
5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon as
they are issued and available).
6. This is done by checking Contractors Special Process Specs against code and SA requirements (SAES-W-011,
Sect 17 for NDT & 13 for PWHT). SAES-W-012 is similar to SAES-W-011 in this respect
7. Ensure that notes are included in these SPECS that require increased NDT based on field welding and other
code considerations.
8. Clear violations such as our weekly highlight example (such as specs and drawings that use 3000# fittings on a
900# system instead of required 6000# fittings) must be itemized & brought to SAPMT attention early.
See attached Sample Weekly Highlight.
9. After all SPECS submitted by Contractor are accepted ... CREATE your custom SPEC-CHECK (sample
attached with instructions).
Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task for
self-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* and
substandard installation identification*.
*FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWARE
OF MANY CRITICAL REQUIREMENTS! SPEC CHECK PUTS THESE DOWN ON PAPER (BY SYSTEM)

Test Package Review & Pre-Hydro Walkdow

1. Follow-up (after initial specification review/approval) can also include checking ISO drawings and bill of materials
against approved specs before Pre-Hydro Walkdown
2. USE YOUR CUSTOM SPEC-CHECK on every new plant project as the perfect walk down and test package
review tool. Important Note: Never assume drawings or test packages are correct. Never assume NDE % & PWHT,
PMI, etc performed/not performed by contractor is correct.
Inspectors must be taught a systematic review method for test packs with focus on Specs.
A thorough test package review system is a page by page review that takes only 15 minutes per package & checks
every page and every weld & all materials for completeness/correctness. Omission of Special Process work by
Contractor is widespread & frequent, most often unintentional and simply due to a lack of AWARENESS.

Surveillance & Focused Assessment

1. Use SPEC-CHECK on routine surveillance.
2. Create a custom SPEC-CHECK for focused assessments on Valves.
Incorrect valve installation is very common with valves placed in the wrong service (swapped, mislocated, mismark)
3. Create a custom SPEC-CHECK for focused assessments on small diameter piping (UT purposes). Past projects
have seen as many as 20% of all piping segments installed of the wrong schedule of piping (J-80, RT Refinery). I
visit projects and find numerous substandard installations very often (human error, again). On your project,
order/request/perform/get Contractor to do random checks of small diameter piping segments (2 & below). I do it
myself with a 2-man crew with me, piping schedules in hand on all my projects & run at about a 2% reject rate.
4. Create a custom SPEC-CHECK for focused assessments on PWHT & BHT. Past projects have seen poor

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 30-Apr-13 Piping-
practice with failure to follow 12-step BHT procedure per NACE RP-0472 App A.
5. Turn your project surveillance into an effective and efficient Inspection asset that is valuable to Projects.

SHARE SPEC CHECK WITH YOUR CONTRACTOR FOR QUALITY

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO TEST REPORT SATR NUMBER DATE APPROVED QR NUMBER

Pre-Pressure Test Checklist (Form) SATR-A-2007 30-Apr-13 MECH-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION TEST SYSTEM No./Test Pack No. PLANT NO.

DRAWING NUMBER (P&ID/ISO) / REV. No. PRESSURE TEST DIAGRAM NATURE OF TEST WORK PERMIT REQD?

SAUDI ARAMCO TIP (SATIP) NUMBER SATIP Activity No. SUPPORTING SAIC Number SAIC QR No.

ATTACHMENT 5 (Guide for Post-Test Reinstatement Checklist by Contractor)

Notes:

1) This Form shall be used in conjunction with applicable Pre-Pressure Test Checklist. Refer to applicable SATIPs & See Attachment 1
2) "A" items are items required to be completed before pressure test can proceed.
3) "B" items are post-test items to be cleared immediately after pressure test (within 24 hours) with Inspection witness per procedure.
4) "B" items are completed during re-instatement per an approved Procedure before final inspection by Company (per procedure).
Note: "B" items not complete during re-instatement (by approved procedure) shall be transferred to "zFEIL Form 6133" (Attachment 2)
5) See SATR-A-2011 for Re-instatement Checklist Form.
6) ETC = Expected Time of Completion or Expected Start-up Date if ETC date is unknown (affects lay-up considerations)
I

Verified Q
T
Pre-Pressure Test Checklist Items & Description Reference
A or Origi- ETC
complete by
Concur
E B nator (Note 6) PID Insp
QC A

1M Seal weld threaded nipples from headers to root valves at (5) locations (hydrocarbon SAES-L-109, RLC
service) per SAES-L-109, Section 8. A ABC/QC 1/1/2007 DEF-1/1/07
Section 8 1/1/07

2 Guides are in direct contact with piping horizontal run at 3 locations (6mm gap req'd).
SAES-L-109, RLC
Relocate guides per drawing. These are welded to the pressure boundary. A ABC/QC 1/1/2007 DEF-1/1/07
Section 8 1/1/07

3 Check valve upstream clearance is not five (5) pipe diameters (40" req'd, 20" actual), in
SAES-L-108, RLC
violation of SAES-L-108. A ABC/QC 1/1/2007 DEF-1/1/07
Section 5 1/1/07

4 Check valve is oriented in the wrong direction (flow arrow). Reverse check valve to
assure correct flow direction. Reposition valve & restore internals immediately after test, SAES-L-108, RLC
B ABC/QC 1/4/2007 DEF-1/4/07
COMPANY to witness. Section 6 1/4/07

5 Piping clearance to structural bracing is 15 mm in violation of SAES-L-310, Sect 12. (50 SAES-L-110, RLC
mm spacing req'd). Engineering! A ABC/QC 1/1/2007 DEF-1/1/07
Section 5 1/1/07

6 Install permanent gaskets at flange sets 1, 4, 5, 6 on ISO dwgs per approved torque SAEP-351, Start-up date =
tables and install spectacle blinds oriented as per approved P&ID. B ABC/QC
Proj Dwgs 5/1/2007

7 Completely remove all water and debris from low point/valve cavity for the (3) in-line
Valves (8" - 300 #) with SS 400 trim, do so immediately after test. Clean with dry
SAES-A-007, RLC
compressed air and relubricate sealing surfaces with approved lubricant in preparation B ABC/QC 1/4/2007 DEF-1/4/07
Para 6.2 1/4/07
for "ambient" lay-up specified in test package.

8 NOTES: a. Above Items are samples for form use.

b. Indicate " No Punch items. " as applicable
c. QA col is reviewed/initialed/dated prior to package certification to
I verify completeness

T Reinstatement (Post-Test) Checklist Items & Reference & Verified Q

A or Origi- ETC Concur
Description (Option per Note 5 Above) Applicable
B nator (Note 6)
complete
PID Insp
SATIP by QC A
E
1 Flushing & hydrotest complete and documented as accepted. Reinstatement
M Procedure

2 All test vents & drains plugged and seal welded ditto
3 Lines drained and lay-up per customer approved specification ditto
4 Valves (400 SS Trim) tested in-line removed, cleaned, & lubricated for Amb lay-up ditto
5 Jacking screws, process blinds (spectacles, spades, etc) correctly installed ditto
6 Spring Hangers & components (bellows, etc) adjusted per mfg instructions. ditto
7 Weepholes plugged with heavy grease (reinforcement pad air test complete) ditto
8 Chain wheel operators installed ditto
9 All instruments, control valves & check valves reinstalled in correct flow position ditto
10 Restriction orifice/flow elements installed ditto
11 Relief Valves are Pop tested/calibrated, tagged and SAP approved/installed ditto
12 All Temporary Test Components (spools, test blinds, gaskets etc) are removed ditto
13 Correct bolts/gaskets are installed and torqued per SAEP-351 requirements ditto
14 Check Valves and internals reinstalled (Internal Cleanliness & gasket check) ditto
15 All Start-up items installed (strainers, filters, other items restricted from test) ditto

Page 15 of 16
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2012) Rev 6 31-Mar-12

SAUDI ARAMCO TEST REPORT SATR NUMBER DATE APPROVED QR NUMBER

Pre-Pressure Test Checklist (Form) SATR-A-2007 30-Apr-13 MECH-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION TEST SYSTEM No./Test Pack No. PLANT NO.

DRAWING NUMBER (P&ID/ISO) / REV. No. PRESSURE TEST DIAGRAM NATURE OF TEST WORK PERMIT REQD?

SAUDI ARAMCO TIP (SATIP) NUMBER SATIP Activity No. SUPPORTING SAIC Number SAIC QR No.

ATTACHMENT 5 (Guide for Post-Test Reinstatement Checklist by Contractor)

16 Chemical Cleaning completed and documented

17 Final Line Check complete & meets all special process specs. See Spec Check.

NOTES: a. Above Items are samples for form use only.

b. Re-instatement Procedure shall detail specific items to be used in this Re-
Instatement checklist (per SAEP-1160, Sect. 8). The above 17 items are a sample
of such a procedure checklist.
c) Indicate " No Post Test items. " as applicable
d). QA col is reviewed/initialed/dated prior to package
certification to verify completeness

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