Saudi Aramco Pressure Testing Procedure

SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008) Rev 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 22-Jan-14 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 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.
Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)
A
Sch Q,
Procedure is project specific, identifiable by Budget Item (BI) or Job
A1
Number, Contract Number & Project title & traceable to Quality Plan.
Para 3.1
A) An approval section exists to document adequacy prior to use.

Sch Q,
B) Revision control section exists to
A2
document procedure changes. (ISO
Para 3.1
9001:2000, Para. 4.2.3a)
Sch Q,
An attachment section exists listing applicable QC forms & records.
A3
(ISO 9001:2000, Para. 4.2.4a)
Para 3.1
Sch Q,
Other sections for special process control procedures (per Sch Q)
A4
detail references, responsibilities, definitions & procedure reqmts.
Para 3.1
Special Process Procedure includes details of Data Mgmt & Tracking

system used for tracking/reporting & the responsibility for following:
A)
Production welds (full pen groove welds*), welder performance, NDE,
PMI, PWHT, BHT & other applicable tests (Ferrite Content, etc)
B) Can S-PM-G000-
identify weld repairs & modifications after acceptance and any need 1520-0006
A5 for follow-up pressure testing or NDT. Also, backlogs. Sec. 8
C) Detailed steps
for Pressure testing package co-ordination with above items
(controls) and pressure testing reporting requirements.
Contractor shall record & track production, inspection & testing of

socket & fillet welds in separate database submitted weekly to
COMPANY.
Page 1 of 21
ITEM
No.
General Requirements
B Note 1: Use SAIC-A-2003 for specific Test package responsibilities & instructions
Note 2: Use SAIC-A-2009 for specific Testing Equipment requirements including Safety Inspections
Procedure lists Pressure Test Package contents as follows:

( 1 ) Reference the "Approved" Pressure Test Procedure
( 2 ) Pressure Test Diagram which shall include the limits of piping
(including test manifold) and equipment included in each pressure
test, high points and low points (drain), locations of pressure gauges,
test pressures, test temperature, test fluid, line flushing requirements,
and safety precautions
( 3 ) Relief valve capacity, testing and installation
( 4 ) Pressure gages and recorders calibration records S-PM-G000-
( 5 ) COMPANY Safety Instruction Sheet (for critical piping) and 1520-0006
Pressure Test Report Form Sec. 10
B1
( 6 ) Copies of P&ID and isometric drawings of the piping system to
be pressure tested
( 7 ) Piping spools control sheet with NDT extent and results.
( 8 ) Pre-pressure test check List
( 9 ) Re-instatement procedure and Check List
( 10 ) Flange set completion documentation for permanent
installations
( 11 ) Identification of pressure testing SPC from CONTRACTOR
( 12 ) Lay-up method to be applied
( 13 ) Verification of chemical dosing calculations when applicable
( 14 ) Test manifold hydro test verification
Procedure (elements) detail GI-2.102 reqmts as follows:

• Pressure Test Diagrams (Use of Test Symbol Legend)
• Test manifold arrangement (GI-2.102 Att. 1 Sect. 5, SAIC-A-2009)
• Location of blind flanges & isolation valves
• Check Valve & sensitive instrument/equipment disposition
• Test limiting factor determination (SIS sheet/Component review)
• Location of test vents, fill points and drains GI-2.102
• Relief Valve capacity, quantity, sizes and set pressure adequacy
• Test medium (water, treated water, lube oil, etc) and cleanliness Attachment
B2
• Test pressure duration and limitations 1
• Special support requirements
• Test sequence (Controlled/staged pressure rise, 10-minute holds) Section 2
• Detailed Inspection & Test Crew responsibilities
during testing
• Safeguards (Personnel clearance, Barricades, signs, permits)
• Staged and safe filling, venting and disposal practices
• Additional personnel & Equipment (radio, signals) used for tests
• Safety Instruction Sheets (Completion & Review Responsibility)
Procedure Equipment section details requirements as listed:

GI-002.102,
• Relief Valve is tested/tagged with set pressure/date (7 Days rule)
Attachment 1,
• Relief valve has adequate capacity (multiple relief for volume test)
Section 5
• No block valves exist in the relief valve inlet or outlet
• Relief valve is located near test pump or medium supply
See Note 2
B3 • Two or more calibrated pressure gauges are used (30 day rule)
&
• Pressure gauges are properly located with block/bleed valves
SAIC-A-2009 /
• Pressure gages at pump or supply are clearly visible to operator
S-PM-G000-
• Blowdown & Isolation valves exist on the test piping
1520-0007
• Blowdown areas are designated for safety (Warning signs)
Sec 6.4
• Manifold is certified/tested to 1.2 times maximum test pressure.
Page 2 of 21
ITEM
No.
Procedures for both hydrotests and service tests address safety
precautions provided in GI-0002.102 "Pressure Testing Safely".
Procedure states: A copy of GI-2.102 and the S-PM-G000-
B4 approved pressure testing procedure shall be kept at test sites. Test 1520-0007
crews and those personnel responsible for pressure testing are Sec-6.5.1
trained and aware of GI and procedural requirements to assure safe
pressure testing
Procedure states: Hydrostatic tests are scheduled as close as

possible to start-up date with minimal time between introducing test
water & commissioning the equipment. Hydrostatic tests and lay-up
S-PM-G000-
procedure shall be designed to protect corrosion-susceptible matls.
B5 114Z-0003,
Sec-6.2
Inspection strategies & plans are prepared and
agreed on prior to commencing fabrication and erection. System
testing & lay-up considerations shall be addressed.
Definitions of various types of pressure tests are listed:
A) Hydrostatic Test, Leak Test, Pneumatic Test, Revalidation Test,
Service Test, Strength Test, Tightness Test.
B) If Valve Field Testing is S-PM-G000-
B6 included in procedure (see API 598), add: 1360-0001,
Valve Shell Test, Sec-2
High-Pressure Closure Test, Low-pressure Closure Test & Backseat
Test. Procedure clearly states
differences between test types
C Pipeline Pressure Testing Applications (Include in procedure if applicable per scope)
Pipeline Strength Tests for New Pipelines are detailed in
procedure and conducted as follows:
A) Strength Test pressure is limited by flanges or
valves in the line.
B) Strength Test pressure is calculated. Hoop
Stress (HS) at 90% of Specified Minimum Yield Strength (SMYS) of
SAES-L-150,
C1 pipe's nominal wall.
Section 8
C) Strength Test pressure at low point considers static head
D) Strength test temperature stresses are not above
SMYS.
E) Strength test pressure is maintained for two hours.
Procedure details calculation checks
and responsibilites
Pipeline Tightness Test is conducted at 95% strength test pressure
immediately after completion of strength test:
A) The tightness test pressure is maintained
as long as required for the inspector to examine all exposed joints.
SAES-L-150,
C2 B) A 24-hour recorded
Section 8
tightness test is done when a pipeline is buried/insulated, or
partially buried/insulated for more than 300 m or 10% of its total
length, whichever is less.
Procedure details Tightness Test parameters
Revalidation Pressure Tests for Existing Pipelines are detailed in

procedure and calculations are checked as follows:
A) Test pressure is
determined (as applicable) as follows:
• minimum of 1.25 times MAOP (with 0.6 & 0.72 design factors) SAES-L-150,
C3
• minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors) Section 8
B) Actual wall thickness & flange rating determines test pressure.
Work is per latest edition of SAEP-310 requirements
for the Repair & Maintenance of Pipelines.
Procedure details: Valve Field Pressure Test Applications, Test

See item D4
C4 Facility, & considerations before, during, and after testing:
below
On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
D
Page 3 of 21
ITEM
No.
Procedure has an On-Plot Piping Pressure Testing Matrix. Define Test

See Attachment 1. This shall cover all tests for On-Plot Workscope
activities and, when reviewed with the Pressure Testing
Specification, shall provide adequate instruction for Test Package &
D1
Development & On-Plot pressure testing & other related testing Specifications
activities including all Utilities (sewer, water), Firewater &
Plumbing systems. Provide clear Sch Q, Att IV,
On-Plot test boundaries & test reqmts. Table 2.1
Procedure states: A hydrostatic strength test shall be applied to

S-PM-G000-
all newly constructed plant piping prior to initial operation per the
D2 1360-0001,
applicable COMPANY requirements and ASME B31.3 or ASME
Sec-23.2
B31.1 except as noted. (Detail Exceptions in procedure)
Procedure details: Valve Pressure Test Applications, Test

Facility, & considerations before, during, and after testing:
A) Applications include Field hydrotesting per
SAIC-L-2042 that follow SAES-L-108, API 598, & ASME B16.34
SAES-L-150,
requirements. Valves require body & seat closure tests per SAES-L-
Section 5.11 /
108, Sect. 4. B) Valve
S-PM-G000-
Testing Facility meets SAIC-L-2031 (See Sections D & J).
1360-0001,
D3 C) In-line testing of valves (body test, seat
Sec-23.11
test restrictions & calcs) D) Post Test draining,
&
cleaning, inspection and preservation details shall be included
SAES-L-108,
whenever valves without drains are tested in-line.
Section 4.7
Valve Testing is included in pressure
testing procedure. See Att 2 (API 598 Definitions, Considerations
for Tests against Valve Seats, Post-Test Valve cavity cleaning &
inspection)
Sampling piping systems are pressure tested as an integral part of S-PM-G000-
D4 the piping or equipment to which it is connected. 1360-0001,
Sec-23.5
S-PM-G000-
Lube and seal oil piping is strength tested in its own fluid at the
D5 1360-0001,
greater of 1.5 times design pressure or 100 psig (≥ 30 minutes).
Sec-23.17 a
Underground process plant piping is tested as follows:
A) Prior to any backfilling for 30 Min.

S-PM-G000-
minimum (Check 100% joints)
D6 1360-0001,
B) If back-filling is required for safety,
Sec-23.17 b
there are two options:
• 100% of weld joints remain fully exposed during the 2 hour test
• 24-hour recorded test is performed if any weld joint is buried
For jacketed piping, the internal line shall be hydrotested according

to paragraph 7.1. All field welds shall be visible for leak detection
during the hydrotest. The jacket shall be hydrotested according to
SAES-L-150
D7 ASME B31.3. The maximum allowable external pressure for the
Para 7.4
internal line shall not be exceeded during the jacket pressure test.
The differential pressure can be minimized by pressurizing the
internal line.
Tie-In butt welds are detailed in hydrotest procedure as follows:

A) Tie-in butt welds (to new or
existing pipe) are Pressure tested S-PM-G000-
D8 B) Test Pressure is based on minimum Code 1360-0001,
requirements if the tie-in is to an existing system. Sec-23.6
C) If a Pressure test is deemed impractical, it can be substituted with
a request of NDT in lieu of pressure testing as processed.
Page 4 of 21
ITEM
No.
Instrument impulse lines are hydrotested only as follows:
A) Liquid test is performed when the test pressure is greater than
1000 psig. Air or nitrogen use is allowed up to 1000 psig.
B) Between root isolation valve & instrument isolation using treated

water (or approved fluid) at 1.25 times system design pressure.
SAES-L-150,
D9
Para 5.12
C) The test duration is not less than 30 minutes.
D) Instrumentation subject to damage from testing is disconnected.
E) When liquid is used in lieu of air,
lines are blown dry after test. See
Attachment 2 for related Flushing/Cleaning Methods
RETESTING of Piping systems that have already successfully

passed a pressure test require a second pressure test if/when:
A) Major Repair of Piping system subject to new
welding activity. Note: This includes
modifications & pressure boundary work.
B) Post-weld Heat Treatment (PWHT) is specified for S-PM-G000-
D10 that line. 1360-0001,
Note: Seal welded threaded connections, non-pressure containing Sec-23.8
welds to attachments (wear pads, etc) are exempt from retesting
unless the line is specified for PWHT.
Procedure details retesting reqmts &
responsibilities, and the Database has capability for tracking
such repairs.
Open-ended Piping (drains, vents & piping downstream of PZVs) S-PM-G000-

D11 discharging directly to atmosphere (max internal pressure 10 psig) is 1360-0001,
not pressure tested. Test Package lists "Visual exam only". Sec-23.9
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060) are

detailed in procedure as follows:
A) Test entire hot or cold water supply system
(test & prove tight) under a water pressure of 1034 kPa (150 psig) for
4 hrs minimum. Note 1: Test all piping
within building from building isolation valve.
Note 2: Water distribution piping network (utility piping from
tankage) to building isolation valve & connected fire hydrants are
tested at 150 psig or 50 psig above maximum operating pressure,
whichever is greater.
Newly SAES-S-060,
constructed water supply systems are disinfected per GI- Para.
D12
0151.006, SA Sanitary Code, Chapter SASC-S-01. The procedure 103.5.3.3
covers this as part of preparation (treatment)
B) Service Test (Check for leaks) shall be performed on
all new equipment connected to water supply lines such as Water
Heaters, Drinking Fountains, etc. that are isolated from the 150 psi
test.6.3 Testing, Inspection and Backfilling
Gravity sanitary sewers, gravity sanitary sewer manholes and
sanitary sewer force mains shall be hydrostatically tested,
inspected, repaired and backfilled in accordance with SAES-S-070.
8-2.2 (Addition)
Disposal of water used for flushing and testing the piping system
shall be in accordance with GI-0432.000. (rescinded)
Page 5 of 21
ITEM
No.
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

S-070, SATIP-S-020) are detailed in procedure as follows:
A) Test entire hot or
cold water supply system (test & prove tight) under a water pressure
of 1034 kPa (150 psig) for 4 hrs minimum.
B) Test Gas Systems (welds & joints accessible) SAES-S-060,
with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not Para.
less than 1-½ times maximum working pressure, but not less than 60 103.5.3.3,
psi (413kPa) for a period of not less than thirty (30) minutes. Para
D13 C) A low pressure air test not exceeding 1204.3.2,
345 kPa (50 psig), & soap bubble test shall be used to test sanitary
drainage or plumbing system of any building premises when there is
reason to believe that it has become defective (damaged during Para.
construction). D) Service Tests 103.5.5.1
(Gravity Tests) shall be performed on all lines. newly constructed,
have been repaired or have otherwise become
contaminated, shall be thoroughly disinfected in accordance with GI-
0151.006,
Saudi Aramco Sanitary Code, Chapter SASC-S-01.
Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

S-070, SATIP-S-020) are detailed in procedure as follows:
A) Test entire hot or
cold water supply system (test & prove tight) under a water pressure
of 1034 kPa (150 psig) for 4 hrs minimum.
B) Test Gas Systems (welds & joints accessible) SAES-S-060,
with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not Para.
less than 1-½ times maximum working pressure, but not less than 60 103.5.3.3,
psi (413kPa) for a period of not less than thirty (30) minutes. Para
D14 C) A low pressure air test not exceeding 1204.3.2,
345 kPa (50 psig), & soap bubble test shall be used to test sanitary
drainage or plumbing system of any building premises when there is
reason to believe that it has become defective (damaged during Para.
construction). D) Service Tests 103.5.5.1
(Gravity Tests) shall be performed on all lines. newly constructed,
have been repaired or have otherwise become
contaminated, shall be thoroughly disinfected in accordance with GI-
0151.006,
COMPANY Sanitary Code, Chapter SASC-S-01.
E Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)
In New Plants, Low pressure steel piping in water, instrument air,

plant air, inert gas (Nitrogen, etc.) & steam systems operating at 150 S-PM-G000-
E1 psig or lower are Service Tested (except FW systems). 1360-0001,
Vessel Trim & Sampling lines also receive a Service Sec-24.3
test.
Service Test After Minor Leak Repairs (in Existing Facilities) is

detailed as follows in the procedure (as applicable per scope):
A) When small diameter threaded piping (in all services/pressures)
S-PM-G000-
repairs are made, thread engagement and seal welding meets S-PM-
E2 1360-0001,
G000-1360-0004 and NDE requirements, followed by Service Test.
Sec-24.1
Seal weld repairs are not
done on Sch. 40 galvanized joints
Page 6 of 21
ITEM
No.
Service Test socket welded piping on Tie-in work & repairs (in
Existing Facilities) if Operations Engineering Unit determines
hydrostatic test is impractical & the following requirements are met:
SAES-L-150,
E3 A) A request of NDT in lieu of pressure testing is processed.
Section 9.2
B) Qualified welders and welding procedures are used.
C) Weld gap is verified & welding is witnessed by Operations Insp.
D) Welds are MT or PT tested (Operations Inspection choice).
Revalidation Tests in Existing Facilities ensure test pressures are

the minimum required by ASME B31.3. Actual wall thickness S-PM-G000-
E4 readings (less than 30 days old) and verified flange rating is taken 1360-0001,
into consideration when calculating the test pressure. Sec-23.17
F Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)
Assembled piping is cleaned/flushed per procedure prior to testing:
A) Water & Pneumatic flushing (SAES-L-350 App. A) See Att # 2
B) Pressurized Air Shock Blowing (PASB) per SAES-L-350 App. A
C) By a Pre-job agreed upon procedure accepted by Company (SA)
PMT, Proponent & Inspection representatives.
SAES-L-350,
F1
Section 15
See Attachment # 2. Cleaning and flushing methods are
incorporated into the procedure & test packages. Valve cavity
(low point) draining, drying, cleaning & reinspection measures
shall be detailed where no low point drains exist.
The general flushing medium is plant/ process water or raw water.
Fire water may be used where process water is not available. Sea
water is not acceptable. Water for hydrostatic test with pH less than 6 S-PM-G000-
F2 and/or SRB counts greater than 10³ per ml is unacceptable.Treat test 114Z-0003,
fluid to control corrosion and bacteria when applicable. Sec-6.1
Employ regular water analysis, maintain
certs and records.
Test Procedure details Lay-up & treatment of Hydrostatic Test Water

for Carbon & Low Alloy Steel systems as follows:
A) Follow 14-day rule with oxygen scavenger & 90-day rule with
biocide use in pipelines, use batching scrapers & nitrogen slug to
separate air from contacting treated water
S-PM-G000-
B) Lay-up per 60-day rule (14 days on exchangers)
F3 114Z-0003
• Wet, Dry, Inert Gas & Ambient Methods are detailed in procedure
Sec-7.1.1
• Boiler Layup is per SAEP-1026, Other methods are COMPANY
approved.
Procedure can utilize S-PM-G000-114Z-0003, Section 7 in
entirety.
Test Procedure details Lay-up & treatment of Hydrostatic Test Water

for Stainless (300, 400 series) systems as follows:
A) Chloride content of test water is tested/certified below 50 mg/L.
B) Test water pH is 10.0 to 11.0 (add approved soda ash/caustic)
S-PM-G000-
C) Treat test water with oxygen scavenger (4-
F4 114Z-0003
day contact rule) D) Treat test water with
Sec-8.1
biocide (14-day contact rule) and lay-up
• Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods
entirety.
Page 7 of 21
ITEM
No.
Special Test preparation requirements are met as follows:

A) Carbon steel atmospheric storage tanks are tested with
plant water (untreated) with all traces of water removed after the test.
B) Potable water systems must treat the water with chlorine or
sodium hypochlorite to effect a residual chlorine concentration
between 0.2 mg/L and 0.5 mg/L for disinfection.
C) Water is untreated for
completely internally coated/lined systems and no lay-up is required S-PM-G000-
F5 for non-metallic systems (e.g., PVC pipe). D) 114Z-0003
For Dry Gas & Refined Hydrocarbon Product Pipelines, oxygen Sec-9
scavenger is added to test water, use batching scrapers & nitrogen
slug to separate contacting treated water (Plant piping exempt)
• Lay-up by drying to dew point of -1°C for corrosion control or as

specified by proponent within 10 days after test & maintained dry.
entirety.
G Detailed Pressure Testing Procedure Requirements (Include applicable requirements)
Hydrotest (Pressure Test) Diagrams and procedures include the

limits of piping (including test manifold) and equipment included in
each hydrostatic test, test pressures, test temperature, test fluid, line
flushing requirements, and safety precautions. S-PM-G000-
G1 Note: Pressure Test diagrams can consist of the following: 1520-0007
• Marked P&IDs & Isometric drawings that use test symbol legend Sec-6.5.1
• Copies of Manifold sketches and manifold test certificates.
• Procedure can allow multiple circuit testing (show jumper hoses)
Test manifolds are certified & tested to 1.2 times maximum test
pressure but not less than discharge pressure of test pump.
S-PM-G000-
Manifold Test Report (Sketch & Certificate) is
G2 1520-0007
required. The sketch lists detailed information/ratings of all
Sec-6.4.4
components. Manifolds receive unique numbers and records are
kept.
Procedure details isolation of test sections (checklist items):
A) Paddle blinds or
spectacle blinds isolate test sections.
B) Blind flanges, pipe plugs and caps isolate S-PM-G000-
G3 test sections 1520-0007
C) Block valve isolation is severely restricted & supported by Sec-8.3
calcs. Fabricated test
implements are rated, marked & inspected
During the application of the test pressure, all in-line valves if not
S-PM-G000-
used as test isolation valves are verified to be in an open position.
G4 1520-0007
Inspectors check valve lineup
Sec-8.3.2
& position prior to testing.
Block valve use for isolation during hydrotest (testing against the seat
of a closed gate, ball or plug valve) is limited & supported with
Engineering calculations (limiting factor considerations) as follows:
A) Test pressures never
exceed seat closure test pressures per API 598 (Example: 150# gate
valve seat closure test is at 314 psi)
S-PM-G000-
B) Valves do not
1520-0007
G5 leakby (Successfully passed a seat closure test)
Sec-8.3
C) Both sides of isolation valve have relief
valves during test.
D) Test pressure is never reduced below 1.5 x
system design pressure per SAES-L-150, Section 7 (ASME B31.3,
Para. 345.4.2) Ensure testing
against valve seats causes no damage.
Page 8 of 21
ITEM
No.
Limiting Factors (test pressures on SIS Sheets/Test Report Forms)

are reviewed by Engineering & verified by Inspection as follows:
• Hoop stress in pipe (nominal wall less mill tolerance) of 90% of
Specified Minimum Yield Strength (SMYS) at test temperature.
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
• Valve pressure rating (1.5xASME B16.34 value, round up 25) SAES-L-150,
G6 • Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design Section 7.1
Attachment 2
• Internal FBE Coating pressure rating is known, listed & considered
Ensure limiting factors are listed (SIS Sheets/test reports)
Prevent overpressurization & damage! See Excel Sheet 3
Components in new piping systems that interfere with filling,

venting, draining or flushing are not installed until after line flushing &
S-PM-G000-
pressure testing are complete. (orifice plates, flow nozzles, sight
G7 1520-0007
glasses, venturies, metering and other in-line equipment.
Sec-8.1.4
List items in procedure and on
reinstatement checklist
Sensitive Equipment excluded from Pressure Test is listed:

A) Rotating machinery, such as pumps, turbines and compressors;
B) Strainers and filter elements
C) Pressure relieving devices (rupture disks & relief valves)
D) Installed system gages where test pressure will exceed range
E) Equipment that cannot be drained & Instrument Devices. S-PM-G000-
G8 F) Other 1520-0007
sensitive equipment designated by SA Inspector* Sec-8.2
*Soft seated valves & control valves are installed
AFTER lines have been thoroughly flushed (SAES-A-004 Para
7.1.3)
List items in procedure and on reinstatement
checklist
Vent & Drain installations for testing purposes are as follows:
A) Vents are provided at all high points in the
piping system. S-PM-G000-
G9 B) Drains are provided at all low points in piping system excluding 1520-0007
submarine and buried pipelines. (Dead legs are not installed) Sec-8.4
This is a
Pre-Hydrotest checklist item verified by Inspection
Relief valves of adequate capacity are set to relieve at 5% above test

pressure. Relief valve(s) are tested, dated, and tagged within one
week prior to the hydrotest for new construction projects. S-PM-G000-
G10 Contractor 1520-0007
maintains list of relief valves and has a COMPANY approved Sec-6.4.1
vendor or system to do weekly calibrations. Inspectors witness
relief valve calibrations
All joints (threaded, welded & flanged) are exposed for visual leak S-PM-G000-
G11 detection during the strength test. External coating/priming of such 1360-0001,
joints is not allowed unless approved by COMPANY. Sec-23.16
Test duration and hold times consider full inspection access via
scaffolding & manlifts as necessary to allow visual inspection of
100% of all joints including weep holes, 6mm drain holes in dummy S-PM-G000-
G12 legs (required). Inspection time may exceed test times listed in SIS 1360-0001,
sheets & Hydrotest reports (30 minute is a minimum). Sec-23.15
Inspectors shall complete inspection before tests
are ended.
Page 9 of 21
ITEM
No.
Temporary supports & other support considerations for above ground

piping installations during hydrotest are as follows:
A) Where
required to prevent damage to system S-PM-G000-
G13 B) As highlighted in the approved 1360-0001,
hydrotesting procedure. C) Sec-25
Expansion joints and spring hangers or spring supports are to be
provided with temporary restraints where needed to prevent
excessive travel or deformation under test loads.
Filling & pressurization is done upstream of check valves in system.

Test fluid enters & drains at lowest points to minimize trapped air.
All vents are open during filling.
Procedure contains the following:
Note: Filling a system too quickly frequently
results in air trapped within the system. This accounts for test
S-PM-G000-
failures and delay due to noticeable pressure drops. Test crews shall
G14 1520-0007
allow additional time (15 minutes average) for air bubbles trapped in
Sec-9.1.1
test water to vent. After such time & fluid levels drop at vents, a final
slow fill is done. Justification
for Note: Thousands of manhours are lost due to test failures
until steps are taken to adequately train test crews to stop
rushing during filling, assure adequate time for proper venting
of air & use a slow final fill technique.
Disposal sites for the test fluid shall be reviewed and approved prior
to the hydrostatic test in accordance with SAEP-327 "Disposal of
S-PM-G000-
Wastewater from Cleaning, Flushing, and Hydrostatic Tests".
G15 1360-0001,
Sec-25.5
Test water reuse is restricted to ensure cleanliness &
quality
After the test pressure is reached and before commencement of

inspection of the system, the isolation valve between the temporary
S-PM-G000-
test manifold/piping and the piping/equipment under pressure test
G16 1520-0007
shall be closed & the test pump disconnected. (Use Bold Letters)
Sec-9.1.2
Note: The isolation valve downstream of the manifold
shall then be opened after the pump has been disconnected.
Pressure gages & recorder requirements are listed as follows:

A) Calibration intervals do not exceed one (1) month.
B) Stickers (signed by Inspection) show latest calibration
date.
C) Gages range for test pressures is 30 to 80% of full range.
S-PM-G000-
D) Two gages (accuracy of each within 5%) are used in testing.
G17 1520-0007
E) When large systems are
Sec-8.1.5
tested, additional gages are required.
F) Recording gauges shall be used where it is necessary to keep a
permanent record, e.g.,when the test duration exceeds four hours, or
otherwise as required by this standard. A
current list of gauges (records) & cal due dates are kept.
If strength test is not practical, it can be substituted with 100% RT & S-PM-G000-
G18 subject to approval by COMPANY 1360-0001,
Process a request of NDT in lieu of pressure testing. Sec-23.7
Hydrotesting (Sample Package & reinstatement):

H (Include/reference reinstatement as referenced
requirements that apply)
Page 10 of 21
ITEM
No.
Test procedure details test package contents as follows:

• Sample Hydrostatic Test Diagram (see 8.01 above)
• Sample Pre-Hydrotest Checklist (sensitive equipment, line flushing)
• Sample Relief Valve Data Sheets & Calibration Records
• Sample Pressure gage & recorders calibration records
• Sample Test Manifold Test Records (1.2 x maximum pressure)
• Sample COMPANYSafety Instruction Sheet & Pressure Test Report S-PM-G000-
H1 Form 1360-0001,
• Sample copy of P&IDs used (test boundaries & symbols) Sec-25.1
• Sample copy of Isometrics used (test boundaries & symbols)
• Sample Piping Spools Control Sheet with NDT extent & Result
• Sample Inspection & Test Plan Sheet (sign offs)
• Sample Re-instatement Check list (Re-instatement is in procedure)
Provide sample test package & procedure for COMPANY
approval.
Removal of Test Components and reinstatement of items after

pressure testing is addressed in the procedure as follows:
A) All
temporary items installed for testing purposes (manifolds, valves,
blinds, spacers, gaskets, supports, etc) are removed.
B) Components that interfered with system
filling/venting/draining & Sensitive Equipment (removed before
S-PM-G000-
testing) are reinstalled. C) Items such
H2 1520-0007,
as instrument air tubing, check valve discs that were disconnected
Sec-10
before testing shall be reconnected.
D) Isolation valves closed for test purposes
required to be in the open position for process reasons shall be
opened. E) If the valve
cavity has a drain, the cavity shall be drained. Test procedure details
test package contents as follows:
Procedure references and details the reinstatement effort
REMARKS:
Pressure Test Procedure (S-PM-G000-1520-0007 Definition): Information assembled to ensure all requirements listed in GI-
0002.102 , all referenced COPMANY & Industrial standards are met. Per S-PM-G000-1520-0007 Definition, test packages are part of
Note
the Pressure Test Procedure. This checklist provides a complete detailing of all Pressure Testing Applications/Requirements for
COMPANY Projects. See Attachment 1. Hydrotest, Pneumatic and Soap Bubble Leak Test*, Service Test, & Valve Testing, can be
1
one (1) procedure (Pressure Testing). *Note: Soap Bubble Leak Test procedure (See SAIC-A-2005) shall meet ASME SEC V Article
10 & Appendix requirements.
Pressure Test Plan is submitted for Company review & contains the following 4 elements necessary to control the work:
1. Pressure Test Procedure (Including Test Package
Note Controls) 2. Sample
Hydrotest Package Per SAIC-2003 3. Hydrotest
2 Data Mgmt & Tracking Database per S-PM-G000-1520-0006
4.
Pressure Testing Specification (Plant Piping System Line Class List modified for Pressure test design)
Note Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and
includes all Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and
3 test package development. Submit early on major projects as Pressure Testing is almost always Critical Path on Projects.
Page 11 of 21
ITEM
No.
Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) &
Note
adoption of Best Practices 2) Meeting Company Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality.
This section is not repeated in other "Review Procedure" type special process checklists, yet is intended for all.
4
ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for COMPANY Projects

Attachment 2 - Pressure Testing Inspection Guide
REFERENCE DOCUMENTS:
1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing (Project Specific)
2. Company General Instruction Manual GI-002.102 Pressure Testing Safely

3. SAEP-1160 Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects
4. S-PM-G000-1520-0007 General Requirements for Pressure Testing
5. S-PM-G000-114Z-0003 Hydrostatic Testing Fluids and Lay-Up Procedures
6 S-PM-G000-1360-0001 GENERAL SPECIFICATION FOR PIPING
7. SAES-L-108 Selection of Valves
8. SAES-L-150 Pressure Testing of Plant Piping and Pipelines
9. SAES-L-310 Design of Plant Piping
10. SAES-L-350 Construction of Plant Piping
11. SAES-S-010 Sanitary Sewers
12. SAES-S-020 Industrial Drainage and Sewers
13. SAES-S-030 Storm Water Drainage Systems
14. SAES-S-040 Saudi Aramco Water Systems
15. SAES-S-050 Sprinkler and Standpipe Systems in Buildings
16. SAES-S-060 Saudi Aramco Plumbing Code
17. SAES-S-070 Installation of Utility Piping Systems
Contractor / Third-Party COMPANY

Construction Representative* Company PMT
Work is Complete and Ready for Inspection: T&I
QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date: Witnessed
Company Inspector
QC Inspector
T&I
Performed Inspection Work / Rework May Proceed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date: Witnessed
QC Supervisor Proponent and Others

Quality Record Approved: T&I
Name, Organization, QC Record Reviewed Work Verified
Name, Sign and Date: Witnessed
Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED
Page 12 of 21
Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 22-Jan-14 MECH-
Attachment 1 - 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
Piping of 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
30 mins (min) psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be
Systems completely 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 2 hrs. B)
A) Process See Notes Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.
Piping If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd.
B) Utility Piping
Flare Lines See Notes Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength
30 tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & mins (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
(150 psig Soap Bubble Test joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and
max) 30 Receiver Service tests and final gasket installation.
mins (min)
LP Steam SERVICE TEST Coordinate with system Service tests and construction completion.
(60 psig max) 30 mins (min)
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
(SAIC- Test at 5-10 psig between the gasket and the seal weld. It shall be examined for leaks using a soap solution.
A-2016)
Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required by
Piping 30 mins (min) the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be
Incl. Tie-Ins determined and taken into consideration when calculating the test pressure. In case of flanged
tie-in connections, a 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
REQMTS welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.
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 EXISTING 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
PIPING pressure shall be in accordance with the requirements of the applicable code.
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
Piping VISUAL EXAM atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc
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
Impulse Lines 30 mins (min) pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or
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).
Page 13 of 21
Internally FBE As Calculated* For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not
Coated Lines 30 mins (min) exceed 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System
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 &
Trim other instruments. Strength or Service test associated piping based on service
(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 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
Piping (Vendor) VENDOR per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct
(exceptions misalignment, physical damage or any modifications in-situ, pressure test the
noted) 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
(Checklist Item D4)
isolation 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.
Page 14 of 21
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.
Page 15 of 21
Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
SAES-L-150 Pressure Testing Definitions
Hydrostatic Test: A pressure test conducted using water or other approved liquid as the test medium.
Leak Test: A pressure test to ensure tightness of flanged and threaded joints at the test
pressure. It is normally conducted before initial start-up & after T&Is. A leak test is different from tightness test
below.
Pneumatic Test: A pressure test conducted using air or other approved gas as the test medium or in conjunction
with liquid.
Revalidation Test: A pressure test performed to prove the integrity of existing pipelines or plant piping.
Service Test: A pressure test performed to prove the integrity of pipelines or plant piping using the service fluid at
the maximum attainable operating pressure.
Strength Test: A pressure test at an internal pressure determined in accordance with this standard and the
applicable Code* to verify the integrity of the piping systems for service at the design pressure.
Tightness Test: Pressure test to ensure piping system tightness (i.e., no system leaks) at
test pressure.
*Strength test (ASME B31.8 code APIterm)
598 is
& same
SA Valve
as aPressure Testing
hydrostatic Definitions
leak test (B31.3) or proof test (B31.4)
Shell (Body Hydrostatic) Test: A pressure test conducted using water or other approved liquid as the test
medium and applying pressure inside the assembled valve with the valve ends closed, the valve partially open &
any packing gland tight enough to maintain test pressure, thus testing the stuffing box.
High-Pressure Closure (Hydrostatic Seat) Test: A pressure test
conducted using water or approved liquid where pressure is applied successively to each side of the closed valve
with the other side open to atmosphere to check for leaks (measured in drops) at the atmospheric side of the
closure.
Low-Pressure Closure (Pneumatic Seat) Test: A pressure test conducted using air (5 psig unless specified
otherwise) where the pressure is applied successively to each side of the closed valve (Flare system valves) with
the other side open to atmosphere to check for leaks (measured in bubbles) at the atmospheric side of the
closure. SAES-L-350 Appendix A (Cleaning Procedures)
Pneumatic flushing with dry air (dew point -1°C or less) or steam with a minimum exit velocity of 15 m/s. Repeat
flushing until cleanliness is verified by observing an absence of any solids impact on a polished metal target at
exit.
Pressurized Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an
alternative method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems
removing trapped liquid in the piping, or to verify cleanliness of small bore pipe where video inspection is
impossible or inadequate due to pipe dimension or configuration. Air shocking pressure shall never exceed
working pressure of the system and shall never be more than 810 kPa (115 psi). Safety precaution shall be
considered in consultation with Area Loss Prevention Division when this method is used. Repeat PASB until
cleanliness is verified by observing the absence of any solids impact on a polished metal target (mirror) at the exit.
Install double filters on air compressors & frequently drain water accumulation to ensure air quality & prevent
fouling of piping systems and instrumentation.
Water Flushing: Equipment sensitive to damage during water flushing shall be removed, blocked off or isolated.
A list shall be prepared and be part of the flushing procedure. Ball valves shall be flushed in fully open position. All
piping systems shall be flushed using high pressure [60.8 mPa (8.8 ksi) minimum] jet such as rotating hose or
rotating nozzle. Below 4", use High Velocity Water Flushing (HVWF). On systems where high pressure jet flushing
cannot be used due to complicated shapes and/or long runs use HVWF or slug flushing. Water velocity shall be a
minimum of 3 m/s. General flushing medium shall be plant/process/raw water. Fire water is used where process
water is not available. Sea water is not acceptable. When flushing stainless steel lines, chloride ion content shall
be less than 50 mg/L. After flushing, piping systems shall be completely drained, dried to a dew point below -1°C
and protected against corrosion. Valve Cavities (low points) without drains shall be addressed in the
procedure.
Mechanical Scrapers: Can be used under the condition that damage to the pipe interior surface shall not occur.
Page 16 of 21
Valve Considerations: Valve Cavities (low points) without drains shall be addressed in the test procedure.
Whenever any valve without a low point drain is tested in-line, steps shall be taken to assure:
1) Complete draining of low points including the valve cavity after testing.
2) Complete removal of debris deposited during flushing and filling. Demonstrate
effectiveness of flushing to prevent debris accumulation in low points. Reinspection after cleaning and
examination of seating surfaces & performance of manufacturer recommended preservation or corrosion control
measures is one acceptable method. Contact CSD.
3) Corrosion Protection measures shall be per SAES-A-007. Ambient lay-up of 400* Series (13Cr) trim
valves, (Trim 1, 4, 6, 7, 8 & 8A) is prohibited without CSD approved corrosion prevention measures.
TEST WITH ISOLATION AGAINST VALVE SEATS (CALCS) PER SAES-A-004, SECTION 7.3
Example 1: A typical Carbon Steel Class 150 # system (Proposed for hydrotest at 450 psi, limiting factor = flange)
1. A test proposes isolatation against a closed valve (gate, ball or plug type). Valve has passed a body & seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 150 # steel gate valve (Refer to ASME B16.34, Group 1.1 Materials tables & Section 7 Pressure Testing & API
598 Table 3 & Table 4) has working pressure design rating of 285 psi.
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (285 x 1.5 = 427.5 = 450 psi)
• Determine Valve Seat/Closure Test pressure. Design = 110% or 1.1 per API 598 Table 3 (285 x 1.1 = 313.5 psi).
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 1 minute (valves to 12” NPS)
Do not allow a 30 minute hydrotest at 450 psi against the valve seat (because overpressurization results).
Resolution: Remove valve from line for test, install a 150# blind flange & proceed with test at 450 psi Or, reduce
test pressure to 313 psi & list valve seat closure as ""limiting factor"" if valve cannot* be removed for test
(*justification
Example #2 (Spec& Company
break approval is required)CS Class 150 # system (hydrotest at 450 psi, limiting factor =
between systems):
flange).
1. Test limit is at a 24” Class 300 # Ball Valve (spec break). Proposed test against valve in closed position. Valve
passed body/seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3
• A 300 # steel ball valve (ASME B16.34, Group 1.1 Matls table & API 598 Tables 3 & 4) has working pressure
design rating of 740 psi
• Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (740 x 1.5 = 1,110 = 1125 psi)
• Determine Valve Seat/Closure Test value. Design x 110% or 1.1 per API 598 Table 3 (740 x 1.1 = 814 psi)
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 2 minutes (valves 14” NPS & over)
Result: Allow 30 minute hydro at 450 psi. Isolation valve is a Higher Class (No seat overpressurization).
LIMITING FACTOR CALCS (PREVENT OVERPRESSURIZATION & POTENTIAL DAMAGE)
Inspectors: Upon receipt of test packages for new systems, Inspectors always review test packages (SIS Sheets
& Test Reports) for errors regarding limiting factor. An organized system of checks takes only minutes per
package.
• Reduce test pressures for metallurgy such as SS, CuNi, Ductile Iron (flanges, valves)
• Reduce test pressures for system limiting factors (flanges, valves, piping of large diameters, internal coatings)
Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are reviewed by Engineering & checked for:
• Flange pressure ratings (1.5xASME B16.5, etc round up 25 value)
• Valve pressure rating (1.5xASME B16.34 value, round up 25)
• Hoop stress in pipe (nom. wall less mill tolerance) of 90% of Specified Min. Yield Strength (SMYS) at test temp
• Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design & considers internal coating maximum
allowable service pressure (SAES-H-102 APCS system 100, 101, 103 = 5,000 psi --- APCS 102 = 3,000 psi)
Ensure limiting factors are listed (SIS Sheets/test reports) and are correct per SAES-L-150, Section 7.1
Example #1: A CS 150 # Raw Water System 12LEOU (hydrotest at 450 psi per SIS, limiting factor = flange)
System has Fusion-bonded epoxy (FBE) internally coated piping & valves (check & gate) for corrosive water
service.
System (ISOs & SIS information match) Design Pressure = 190 psi at Design temperature of 100F. Piping is
shown on drawings to be API 5L, Gr B seamless pipe 24” Standard or .375” nominal wall, also 12” Standard or .
375” Pipe flanges are ASTM A 105, forged CS, per ASME 16.5. A 150 # gate valve in this service is Ductile iron
ASTM A395 epoxy lined body, Bolted Bonnet, ASTM B61/B62 bronze trim. A 150 # check valve in this service is
Ductile iron ASTM A395 epoxy lined body, Bolted Cover, ASTM B61/B62 bronze trim. Note: The system test will
cover three open gate valves, one check valve (internals removed for test), and one closed gate valve.
Page 17 of 21
Quick Calc Steps: 1. Do not accept a test in 150# system against a closed 150# valve (typical for all classes)
Do not accept the proposed test against a closed gate valve. Perform thorough review even after finding an error.
2. Determine Flange Pressure ratings as follows:
• Pipe flg limiting factor per ASME B16.5 (Table 1-A, Mat'l Group 1.1 = ASTM A 105) Press Temp Rating Table 2-
1.1
• Working pressure rating for Class 150 systems @ temp of 100 F = 285 psig (multiply value by 1.5 per Section
8.3)
• 285 x 1.5 = 427.5, round up to next increment of 25 = 450 psig (acceptable, as our listed limiting factor is 450
psi)
3. Determine Valve Pressure ratings by checking ASME B16.34 OR API 598 Table 2 & 3
Note: Class 150 Ductile Iron = 400 psig per Table 2 (shell test) & 250 psig (high
pressure seat closure test)
ACTIONS: Do not accept 450 psig test pressure. Class 150 valves (ductile iron) are tested to 400 psig (250 at
seat). B) Request a test pressure reduction to 400 psig and test limit revision & proceed with
Formula for pressure
review, even is P = t x 2S(0.9)(E) / D
after 2 errors.
S
4. =Determine
Stress Values
pipingfrom ASMEratings
Pressure B31.3asTable A-1 in
follows (API
the5L Gr. B has
following a SMYS
code formulaof based
35,000)
ontherefore
90% SMYS S = (per
35,000
SA):
tUse
= pipe
ASMEthickness (nominal
B31.3 code less t12.5
formula = PD%/ mill
2SEtolerance for seamless
& SA requirement of pipe, less 0.10”
90% SMYS for welded
values plate) test calcs.
for strength
Therefore .375” x 87.5%, t = .328” for both 12” & 24” seamless pipe
P = unknown & E = Quality Factor from Table A-1A or Table A-1B (Quality factor for API 5L Seamless Pipe is
1.00), therefore E = 1.00
D = outside diameter of piping (all sizes are considered in calcs), therefore 2 calcs will be performed, one for 24”
and the other for 12”
Calc for 12” pipe ... P=.328 x (2)(35,000)(0.9) / 12 = 1,722.66 or 1,723 psi is rating for limiting factor for 12”
pipe
Calc for 24” pipe ... P=.328 x (2)(35,000)(0.9) / 24 = 861.33 or 861 psi is rating for limiting factor for 24” pipe
Notice how pipe diameter affects pressure! Neither pipe size is near our 400 psi limiting factor
5.Check FBE internal coating spec (APCS 101) indicates pressure rating of 5,000 psi per SAES-H-002, not a
factor!
ACTION: Review Complete. Return test package to Engineering. Test pressure and arrangement are
unacceptable: 1. Test pressure of 450 psig is unacceptable as Ductile Iron Valves are rated for 400
psig.
2. Use of a closed ductile iron valve at test limits is unacceptable.
Recommendation: Reduce Test pressure to 400 psig. Test valves in open position with blind at test limit.
Page 18 of 21
Attachment 3 - Saudi Aramco Pressure Testing Inspection Guide For Procedures
OVER PRESSURIZATION ALERT FOR LATERALS
1. 100% HOLD POINT ON LATERAL BRANCH CONNECTION WELDS FOR COMPANY

VISUAL EXAMINATION OF ROOT ID. MEANS OF VISUAL EXAM MUST BE PROVIDED
(EXTENSION MIRROR / REMOTE VIDEO). USE WINDOW TECHNIQUE FOR ROOT EXAM
2. LATERALS MUST RECEIVE NDE ON
ANY EXISTING / SUSPECT ROOT CONDITIONS TO PREVENT POSSIBILITY OF FAILURE
DURING PRESSURE TESTING. 3. FULL ENCIRCLEMENT
SLEEVES MUST REINFORCE ALL LATERALS.
4. LESSONS LEARNED (HAWIYEH FATALITY) ... NEVER ALLOW
LATERALS ON ANY SYSTEM ABOVE CLASS 150# ... CALCS PER ASME B31.3 Appendix
H apply. Do not allow overpressurization. See acceptable detail below. Angle may vary.
Page 19 of 21
OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)
Page 20 of 21
Page 21 of 21

Saudi Aramco Pressure Testing Procedure

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Saudi Aramco Pressure Testing Procedure

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SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008) Rev 3 30-Jun-08

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

A) An approval section exists to document adequacy prior to use.

Special Process Procedure includes details of Data Mgmt & Tracking

Contractor shall record & track production, inspection & testing of

Procedure lists Pressure Test Package contents as follows:

Procedure (elements) detail GI-2.102 reqmts as follows:

Procedure Equipment section details requirements as listed:

Procedure states: Hydrostatic tests are scheduled as close as

Revalidation Pressure Tests for Existing Pipelines are detailed in

Procedure details: Valve Field Pressure Test Applications, Test

Procedure has an On-Plot Piping Pressure Testing Matrix. Define Test

Procedure states: A hydrostatic strength test shall be applied to

Procedure details: Valve Pressure Test Applications, Test

A) Prior to any backfilling for 30 Min.

For jacketed piping, the internal line shall be hydrotested according

Tie-In butt welds are detailed in hydrotest procedure as follows:

B) Between root isolation valve & instrument isolation using treated

RETESTING of Piping systems that have already successfully

Open-ended Piping (drains, vents & piping downstream of PZVs) S-PM-G000-

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060) are

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-

In New Plants, Low pressure steel piping in water, instrument air,

Service Test After Minor Leak Repairs (in Existing Facilities) is

Revalidation Tests in Existing Facilities ensure test pressures are

Test Procedure details Lay-up & treatment of Hydrostatic Test Water

Test Procedure details Lay-up & treatment of Hydrostatic Test Water

Special Test preparation requirements are met as follows:

• Lay-up by drying to dew point of -1°C for corrosion control or as

G Detailed Pressure Testing Procedure Requirements (Include applicable requirements)

Hydrotest (Pressure Test) Diagrams and procedures include the

• Procedure can allow multiple circuit testing (show jumper hoses)

Limiting Factors (test pressures on SIS Sheets/Test Report Forms)

Ensure limiting factors are listed (SIS Sheets/test reports)

Prevent overpressurization & damage! See Excel Sheet 3

Components in new piping systems that interfere with filling,

Sensitive Equipment excluded from Pressure Test is listed:

Relief valves of adequate capacity are set to relieve at 5% above test

Temporary supports & other support considerations for above ground

Filling & pressurization is done upstream of check valves in system.

After the test pressure is reached and before commencement of

Pressure gages & recorder requirements are listed as follows:

Hydrotesting (Sample Package & reinstatement):

Test procedure details test package contents as follows:

Removal of Test Components and reinstatement of items after

ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for COMPANY Projects

2. Company General Instruction Manual GI-002.102 Pressure Testing Safely

Contractor / Third-Party COMPANY

QC Supervisor Proponent and Others

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

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

1. 100% HOLD POINT ON LATERAL BRANCH CONNECTION WELDS FOR COMPANY

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