SAIC-A-2001 Rev 3 Review Procedure Pressure Testing (All Applications)

8/13/2019 SAIC-A-2001 Rev 3 Review Procedure Pressure Testing (All Applications)

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A7

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 identify weld repairs & modifications after acceptance and any

need for follow-up pressure testing or NDT. Also, backlogs.

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 SA

SAEP-1160,

Section 6

(Data Elements)

EQPT CODE SYSTEM ID.

A6Other sections for special process control procedures (per Sch Q) detail

references, responsibilities, definitions & procedure reqmts.

Sch Q,

Para 3.1

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER

LAYOUT DRAWING NUMBER

PLANT N

REV. NO.

WORK PERMIT

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION

SCHEDULED INSPECTION DATE & TIME MH's SPENTQUANTITY INSP.ACTUAL INSPECTION DATE & TIME

SAUDI ARAMCO USE ONLYTRAV

EC / PMCC / MCC NO.PURCHASE ORDER NUMBER

A

SAUDI ARAMCO ACTIVITY NUMBER

CONTRACTOR INSPECTION LEVELSAUDI ARAMCO INSPECTION LEVEL

SAUDI ARAMCO TIP NUMBER

ITEM

No.ACCEPTANCE CRITERIA RE-INSPASSREFERENCE FAIL N/A

A5An attachment section exists listing applicable QC forms & records.

(ISO 9001:2000, Para. 4.2.4a)

Sch Q,

Para 3.1

Sch Q,

CPI clause

Sch Q,

Para 3.1

Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)

A3

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

B) Revision control section exists to document procedure changes.

(ISO 9001:2000, Para. 4.2.3a)

Sch Q,Para 3.1

A1

Procedure Scope Sectioncontains a section for Quality Goals &

Continuing Process Improvement, customer satisfaction, & lists

quality goals (following example provided):

When made evident through documentation of field deficiencies or whenrequested by SA, revisions to improve this document and other quality

awareness corrective and preventive actions shall be taken in a

Continuing Process Improvement (CPI) effort targeting Project Quality

Goals such as Customer Satisfaction, reduction of costly rework, &

Savings through Quality. Such Revisions shall correct errors,

deficiencies, omissions or detail more thoroughly quality elements to

provide adequate field instruction in an effort to meet SA Stds & Industry

Best Practices for Pressure Testing.

Alternative: QP covers this & regu lar Quality Review shall identify

defic iencies for Procedural Improvem ent & corrective action.

A2Procedure is project specific, identifiable by Budget Item (BI) or Job

Number, Contract Number & Project title & traceable to Quality Plan.

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No.ACCEPTANCE CRITERIA REFERENCE


FAIL N/A

General Requirements

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

PASS

GI-2.102

Attachment 1Section 2

WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 MECH-

SAUDI ARAMCO INSPECTION CHECKLIST

PROJECT TITLE

Procedure Equipment or Safety section details regular safety

inspections & maintenance of test equipment per SAIC-A-2009.B5

B

B1

Procedure lists Pressure Test Package contentsas follows:

Reference "Approved" Pressure Test Procedure

Pressure Test Diagram* which shall include the limits of piping

(including test manifold arrangement) & equipment included in each

pressure test, high points & low points (vent, drain), locations of pressure

gauges, test pressures, test temperature, test fluid, line flushing reqmts

& safety precautions (*Use a test symbol legend)

Relief valve capacity, testing and installation

Pressure gages and recorders calibration records

SA Safety Instruction Sheet (critical piping), Pressure Test Report

Copies of P&ID & ISOs of the piping system to be pressure tested

Piping spools control sheet with NDT extent and results.

Pre-pressure test check List

Re-instatement procedure and Check List Flange set completion documentation for permanent installations

Identification of pressure testing SPC from contractor

Lay-up method to be applied

Verification of chemical dosing calculations when applicable

Test manifold hydro test verification

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 approved pressure testing

procedure shall be kept at test sites. Test crews and those personnel

responsible for pressure testing are trained and aware of GI and

procedural requirements to assure safe pressure testing

Procedure (elements) detail GI-2.102 reqmtsas 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

Relief Valve capacity, quantity, sizes and set pressure adequacy

Test medium (water, treated water, lube oil, etc) and cleanliness Test pressure duration and limitations

Special support requirements

Test sequence (Controlled/staged pressure rise, 10-minute holds)

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)

B4

B2

B3

SAEP-1160,

Section 8

See Note 1 &

SAIC-A-2003

Procedure Equipment sectiondetails requirements as listed:

Relief Valve is tested/tagged with set pressure/date (7 day rule)

Relief valve has adequate capacity (multiple relief for volume test)

No block valves exist in the relief valve inlet or outlet

Relief valve is located near test pump or medium supply

Two or more calibrated pressure gauges are used (30 day rule) Pressure gauges are properly located with block/bleed valves

Pressure gages at pump or supply are clearly visible to operator

Blowdown & Isolation valves exist on the test piping

Blowdown areas are designated for safety (Warning signs)

Manifold is certified/tested to 1.2 times maximum test pressure.

GI-002.102,

Attachment 1,

Section 5See Note 2 &

SAIC-A-2009

See Note 2 &

SAIC-A-2009

SAES-A-004,

Section 5.7

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PROJECT TITLE

Define Test

Workscope

& Specifications

Sch Q, Att IV,

Table 2.1

C3

C4

SAES-L-150,

Section 8

Pipeline Pressure Testing Applications (Include in procedu re if applicable per scop e)

On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)

Pipeline Tightness Testis 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.

B) A 24-hour recorded tightness testis 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 detai ls Tightness Test parameters

Procedure has an On-Plot Piping Pressure Testing Matrix.

See Attachment 1. This shall cover all tests for On-Plot activities and,

when reviewed with the Pressure Testing Specification, shall provide

adequate instruction for Test Package Development & On-Plot pressure

testing & other related testing activities including all Utilities (sewer,

water), Firewater & Plumbing systems.

Provide clear On-Plot test boundaries & test reqm ts.

SAES-L-150,

Section 8

Procedure details: Valve Field Pressure Test Applications, Test

Facility, & considerations before, during, and after testing:

See item D4

below

SAES-L-150,

Section 5

SAES-A-007,

Section 5.7

C

D3

Vessel Trim receives a strength test except for vessel trim in Utility

services tested at 150 psi and less (conduct a service test).

Clearly identi fy Vessel & Piping Code test boun dary l imits.

C1

Pipeline Strength Tests for New Pipelinesare detailed in procedureand 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 pipe's nominal wall.

C) Strength Test pressure at low point considers static head

D) Strength test temperature stresses are not above SMYS.

E) Strength test pressure is maintainedfor two hours.

Procedure detai ls calculat ion checks and respons ibi l i tes

C2

D

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)

minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors)

B) Actual wall thickness & flange rating determines test pressure.

Work is p er latest edit ion o f SAEP-310 requirements for the Repair

& Maintenance of Pipel ines.

D2

Procedure states: A hydrostatic strength testshall be applied to all

newly constructed plant pipingprior to initial operation per the

applicable SA requirements and ASME B31.3 or ASME B31.1 except as

noted. (Detai l Exceptions in pro cedure)

SAES-L-150,

Section 8

Definitions of various types of pressure tests are listed:

A) Hydrostatic Test, Leak Test, Pneumatic Test, Revalidation Test,

Service Test, Strength Test, Tightness Test (SAES-L-150, Sect. 4)

B) If Valve Field Testing is included in procedure (see API 598), add:

Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure

Test & Backseat Test (SAES-L-108, Section 4.7.6)

Procedure clearly states differences between test types

B6

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 procedureshall be designed to protect corrosion-susceptible matls.

Inspection strategies & plans are prepared and agreed on prior to

commencing fabrication and erection. System testing & lay-up

considerations shall be addressed (SAES-L-350, Para. 17.2)

SAES-L-150,

Section 5

D1

B7

SAES-L-150,

Section 4

See also

Attachment 2

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PROJECT TITLE

SAES-L-150,

Section 5.9D12

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

discharging directly to atmosphere (max internal pressure 10 psig) is not

pressure tested. Test Package lists "Visual exam only".

D11

RETESTING of Piping systemsthat have already successfully passed

a pressure test require a second pressure test if/when:

A) Major Repairof Piping system subject to new welding activity.

Note: This includes modifications & pressure boundary work.

B) Post-weld Heat Treatment (PWHT) is specifiedfor that line.

Note: Seal welded threaded connections, non-pressure containing welds

to attachments (wear pads, etc) are exempt from retesting unless the

line is specified for PWHT.

Procedure detai ls retest ing reqmts & respo nsibi l i t ies, and the

Database has capabil i ty for trackin g suc h repairs.

SAES-L-150,

Section 5.8

Instrument impulse linesare 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 timessystem design pressure.

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 Flushin g/Cleaning Metho ds

SAES-L-150,

Para 5.12

D8

Jacketed piping exams & hydrotest sequence are detailed in the test

procedure (code references apply):

A) Inner lines are accepted & all exams (visual, NDE, etc) are complete

& acceptable prior to strength testinginternal piping.

B) Inner piping joints are 100% visually accessible for pressure test

C) Outer pipe split fitting design for branches allows joint access.

D) Outer pipe is centered with spacers seal welded to inner pipe.

Jacket material design & instal lat ion sequence meets code.

E) Service testingcan be performed on the outer steam piping.

Detai l any ch art recorder use (24-hour supp lemental test)

ASME B31.3,

Section 345.2.5

D9

Sampling piping systemsare pressure tested as an integral part of the

piping or equipment to which it is connected.

SAES-L-150,

Section 5

SAES-L-150,

Section 5.11

& SAES-L-108,

Section 4.7

D6Lube and seal oil pipingis strength tested in its own fluid at the greater

of 1.5 times design pressure or 100 psig (for 30 minutes).

SAES-L-150,

Section 7.4

SAES-L-150,

Section 7.4

Underground process plant pipingis tested as follows:A) Prior to any backfilling for 2 hoursminimum (Check 100% joints)

B) If back-filling is required for safety, there are two options:

100% of weld joints remain fully exposed during the 2 hour test

24-hour recorded testis performed if any weld joint is buried

Tie-In butt weldsare detailed in hydrotest procedure as follows:

A) Tie-in butt welds (to new or existing pipe) are strength tested

B) Strength Test Pressure is based on minimum Code requirements if

the tie-in is to an existing system.

C) If a strength test is deemed impractical, it can be substituted with a

request of NDT in lieu of pressure testing as processed.

SAES-L-150,

Section 5

D10

D4

Procedure details: Valve Pressure Test Applications, Test Facility, &

considerations before, during, and after testing:

A) Applications include Field hydrotesting per SAIC-L-2042that followSAES-L-108, API 598, & ASME B16.34 requirements. Valves require

body & seat closure tests per SAES-L-108, Sect. 4.

B) Valve Testing Facility meets SAIC-L-2031 (See Sections D & J).

C) In-line testing of valves (body test, seat test restrictions & calcs)

D) Post Test draining, cleaning, inspection and preservation details shall

be included whenever valves without drains are tested in-line.

Valve Testing is in cluded in p ressure testing pro cedure. See Att 2

(API 598 Definit ions, Consid erations for Tests against Valve Seats,

Post-Test Valve cavity cleaning & in spection )

D5

D7

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PROJECT TITLE

F

E4

Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the pro cedure)

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)

repairs are made, thread engagement and seal welding meets SAES-L-

110 and NDE requirements, followed by Service Test.

Seal weld repairs are not do ne on Sch . 40 galvanized joints

SAES-L-150,

Section 9.1

Revalidation Tests in Existing Facilities ensure test pressures are the

minimum required by ASME B31.3. Actual wall thickness readings

(less than 30 days old) and verified flange rating is taken into

consideration when calculating the test pressure.

SAES-L-150,

Section 7.5

E3

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:

A) A request of NDT in lieu of pressure testing is processed.

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).

SAES-L-150,

Section 9.2

E2

E

E1

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

air, inert gas (Nitrogen, etc.) & steam systems operating at 150 psig or

lower are Service Tested(except FW systems).Vessel Trim & Samplin g l ines also receive a Service test.

SAES-L-150,

Section 9.3

Service Test, Leak Test, Minor Repair & Other Applications ( Include & detai l Service Test l imitat ions per scop e)

D15

ressure es s or um ng - - , - - , - -

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) with air, CO2, or

nitro en Ox en rohibited at test ressure not less than 1- times

SAES-S-060,

Para. 103.5.3.3,

Para 1204.3.2,

Para. 103.5.5.1

D14

- - , - - , - -

070, SATIP-S-020) are detailed in procedure as follows:A) Test entire hot or cold water supply system (test & prove tight) under


B) Test Gas Systems (welds & joints accessible) with air, CO2, or

nitro en Ox en rohibited at test ressure not less than 1- times

SAES-S-060,Para. 103.5.3.3,

Para 1204.3.2,

Para. 103.5.5.1

D13

- - , - -

detailed in procedure as follows:

A) Test entire hot or cold water supply system (test & prove tight) under


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 constru cted water supply system s are disinfected per GI-

0151.006, SA Sanitary Co de, Chapter SASC-S-01. The proc edure

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

SAES-S-060,

Para. 103.5.3.3

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PROJECT TITLE

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 system test water is treated with chlorine or sodium

hypochlorite for disinfection (with dry or ambient lay-up).

C) Water is untreated for completely internally coated/lined systems and

no lay-up is required for non-metallic systems (e.g., PVC pipe).

D) For Dry Gas & Refined Hydrocarbon Product Pipelines, oxygen

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 -1C for corrosion control or as

specified by proponent within 10 days after test & maintained dry.

Procedure c an uti l ize SAES-A-007, Section 7 in entirety

SAES-A-007

Section 7

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

Stainless (300, 400 series) systemsas 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)

C) Treat test water with oxygen scavenger (4-day contact rule)

D) Treat test water with biocide (14-day contact rule) and lay-up

Wet, Dry, Inert Gas & Ambient (40% humidity limit) MethodsProcedure c an uti l ize SAES-A-007, Section 6 in entirety

SAES-L-350,

Section 15

SAES-A-007

Section 6

F2

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 and/or

SRB counts greater than 10 per ml is unacceptable. Treat test fluid to

control corrosion and bacteria when applicable.

Emplo y regular water analysis, maintain certs and record s.

F3

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

Carbon & Low Alloy Steel systemsas 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

B) Lay-up per 60-day rule (14 days on exchangers)

Wet, Dry, Inert Gas & Ambient Methods are detailed in procedure

Boiler Layup is per SAEP-1026, Other methods are CSD approved

Procedure c an uti l ize SAES-A-007, Section 5 in entirety

F4

SAES-A-007

Section 5

G

F1

F5

G1

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.

Note: Pressure Test diagrams can consis t of the fol lowing:

Marked P&IDs & Isometric drawings that use test symbol legend

Copies of Manifold sketches and manifold test certificates.

Procedure can allow multiple circuit testing (show jumper hoses)

SAES-A-004,

Section 5.6

SAES-A-007

Section 4

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. AC) By a Pre-job agreed upon procedure accepted by Company (SA)

PMT, Proponent & Inspection representatives.

See Attachm ent # 2. Cleaning and flushing method s are

incorp orated into the procedu re & test packages. Valve cavity (low

point) draining, drying , cleaning & reinspection m easures shall be

detai led where no low poin t drains exist.

Detailed Pressure Testing Procedure Requirements (Include applicable requirements)

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G9

Vent & Drain installationsfor testing purposes are as follows:

A) Vents are provided at all high points in the piping system.

B) Drains are provided at all low points in piping system excluding

submarine and buried pipelines. (Dead legs are not instal led)

This is a Pre-Hydrotest check l ist item verif ied by Inspection

SAES-L-150,

Section 6

G7

Components in new piping systems that interferewith filling, venting,

draining or flushing are not installed until after line flushing & pressure

testing are complete. (orifice plates, flow nozzles, sight glasses,

venturies, metering and other in-line equipment.

List items in procedure and on reinstatement checkl ist

SAES-A-004

Para 7.1.4

G8

Sensitive Equipment excluded from Pressure Testis 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.F) Other sensitive equipment designated by SA Inspector*

*Soft seated valves & co ntrol valves are instal led AFTER lines have

been tho rough ly flus hed (SAES-A-004 Para 7.1.3)

List items in procedure and on reinstatement checkl ist

SAES-A-004

Para 7.2

G5

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)

B) Valves do not leakby (Successfully passed a seat closure test)

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 agains t valve seats causes no damage.

SAES-A-004,

Para 7.3 &

Attachment 2

G6

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)

Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design

Internal FBE Coating pressure rating is known, listed & considered

Ensure l im it ing factors are l isted (SIS Sheets/test reports)

Prevent overpressurizat ion & damage! See Excel Sheet 3

SAES-L-150,

Section 7.1

Attachment 2

G3

Procedure details isolation of test sections (checklist i tems):

A) Paddle blinds or spectacle blinds isolate test sections.

B) Blind flanges, pipe plugs and caps isolate test sections

C) Block valve isolation is severely restricted & supported by calcs.

Fabricated test implements are rated, marked & insp ected

SAES-A-004,

Para 7.3

G4

During the application of the test pressure, all in-line valves if not used

as test isolation valves are verified to be in an open position.

Inspectors check valve lineup & posit io n prior to test ing.

SAES-A-004,

Para. 8.1.3

Test manifolds are certified & tested to 1.2 times maximum test pressure

but not less than discharge pressure of test pump.

Manifold Test Report (Sketch & Cert i f icate) is required. The sketchl ists detai led inform ation/rat ings of al l com ponen ts. Manifolds

receive unique numb ers and records are kept.

SAES-A-5.5.4G2

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HHydrotesting (Sample Package & reinstatement):

(Include/reference reinstatement requirem ents that apply)as referenced

G18

If strength test is not practical, it can be substituted with 100% RT &

subject to approval by Inspection Department Mgr. for new projects.

Process a request of NDT in l ieu of press ure testing.

SAES-A-004,

Section 5.7

G17

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.

D) Two gages (accuracy of each within 5%) are used in testing.

E) When large systems are tested, additional gages are required.

A curr ent l ist of gauges (records) & cal du e dates are kept.

SAES-A-004

Para 7.1.5

G15

Disposal sites for the test fluid shall be reviewed and approved prior to

the hydrostatic test in accordance with SAEP-327 "Disposal of

Wastewater from Cleaning, Flushing, and Hydrostatic Tests".

Test water reuse is restr icted to ensure cleanliness & qu ali ty

SAES-L-150,

Section 11

G16

After the test pressure is reached and before commencement of

inspection of the system, the isolation valve between the temporary test

manifold/piping and the piping/equipment under pressure test shall be

closed & the test pump disconnected. (Use Bold Letters)

Note: The isolation valve downstream of the manifold shall then be

opened after the pump has been disconnected.

SAES-A-004,

Para. 8.1.2

G14

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 failures and delay due to noticeable

pressure drops. Test crews shall allow additional time (15 minutes

average) for air bubbles trapped in test water to vent. After such time &

fluid levels drop at vents, a final slow fill is done.

Just i f icat ion for Note: Thousands of m anhours are lost due to test

fai lures unti l steps are taken to adequately train test crews to stop

rushin g during fi l l ing , assure adequate time for proper venting of

air & use a slow fin al f i l l techniq ue.

SAES-A-004

Para 8.1.1

G13

Temporary supports & other support considerations for above ground

piping installations during hydrotest are as follows:

A) Where required to prevent damage to system

B) As highlighted in the approved hydrotesting procedure.

C) 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.

SAES-L-150,

Section 6

SAES-A-004Para 5.5.1

G12

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 legs

(required). Inspection time may exceed test times listed in SIS sheets &

Hydrotest reports (30 min ute is a minimu m).

Inspectors shall com plete inspection before tests are ended.

SAES-L-150,

Para. 5.12.2

G11

All joints (threaded, welded & flanged) are exposed for visual leak

detection during the strength test. External coating/priming of such joints

is not allowed unless approved by ID Manager & Proponent

SAES-L-150,

Section 7.3

G10

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.Contractor m aintains l ist of rel ief valves and has a SA approved

vendor or system to do weekly cal ibrat ions. Inspecto rs witness

rel ief valve calibrat ions

Page 8 of 15


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PROJECT TITLE

Note

1

Pressure Test Procedure (SAES-A-004 Definition):Information assembled to ensure all requirements listed in GI-0002.102 , all refere

SA & Industrial standards are met. Per SAES-A-004 Definition, test packages are part of the Pressure Test Procedure. This checklist

provides a complete detailing of all Pressure Testing Applications/Requirements for SA Projects. See Attachment 1.

Hydrotest, Pneumatic and Soap Bubble Leak Test*, Service Test, & Valve Testing, can be one (1) procedure(Pressure Testing).Sma

projects (less than 500 welds) do not require a Database for tracking welds & test packages per SAEP-1160 requirements.

*Note: Soap Bubble Leak Test procedure (See SAIC-A-2005) shall meet ASME SEC V Article 10 & Appendix requirements.

Note

2

Pressure Test Planis submitted for Company review & contains the following 4 elements necessary to control the work:

1. Pressure Test Procedure(Including Test Package Controls)

2. Sample Hydrotest Package Per SAIC-2003 3

Hydrotest Data Mgmt & Tracking Database per SAEP-1160

Small projects (less than 500 welds) do not require a Database for tracking welds & test packages per SAEP-1160 requirements.

4. Pressure Testing Specification (Plant Piping System Line Class List modified for Pressure test design)

Note

3

Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes a

Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and test package

development. Submit early on major projects as Pressure Testing is almost always Critical Path on Projects.

Note

4

Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) & adoptio

Best Practices 2) Meeting SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality. This sect ion

not repeated in other "Review Procedu re" type special process c heckl ists, yet is intended for al l .

H1

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 SA Safety Instruction Sheet & Pressure Test Report Form

Sample copy of P&IDs used (test boundaries & symbols)

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 samp le test package & proc edure for SA approval.

SAES-L-310,

Section 22

H2

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 testing) are reinstalled.

C) Items such as instrument air tubing, check valve discs that were

disconnected 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 d etai ls the reinstatement effort

SAES-L-310,

Section 22

5. SAES-A-007 (5 October 2005) Hydrostatic Testing Fluids and Lay-Up Procedures

2. SA General Instruction Manual GI-002.102 (July 22, 2001) Pressure Testing Safely

3. SAEP-1160 (17 July 2006) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects

1. Contract Schedule Q - Quality Assurance and Control, Inspection and Testing

REFERENCE DOCUMENTS:

4. SAES-A-004 (30 March 2005) General Requirements for Pressure Testing

REMARKS:

ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA Projects

Attachment 2 - Pressure Testing Inspection Guide

Page 9 of 15


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WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACT


Review Procedure Pressure Testing (All Applications) SAIC-A-2001 1-Dec-06 M


PROJECT TITLE

*Person Responsible for Completion of Quality Work / Test Y = YES

QC Supervisor Proponent and Others

Name, Sign and Date:Quality Record Approved:

Name, Organization,

Initials and Date:

T&I W itnessed QC Record Reviewed

QC Inspector PID Representative

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

Name, Initials and Date:T&I W itnessed QC Record Reviewed

Construction Representative* PMT Representative

Name, Initials and Date:Work is Complete and Ready for Inspection:

Name, Initials and Date:T&I W itnessed QC Record Reviewed

6. SAES-L-108 (21 December 2005) Selection of Valves

Contractor / Third-Party Saudi Aramco

8. SAES-L-310 (30 September, 2003) Design of Plant Piping

14. SAES-S-050 (30 August 2000) Sprinkler and Standpipe Systems in Buildings

16. SAES-S-070 (28 September 2005) Installation of Utility Piping Systems

11. SAES-S-020 (30 November 2002) Industrial Drainage and Sewers

12. SAES-S-030 (August 2005) Storm Water Drainage Systems

13. SAES-S-040 (31 December 2003) Saudi Aramco Water Systems

15. SAES-S-060 (28 January 2004) Saudi Aramco Plumbing Code

7. SAES-L-150 (30 September, 2003) Pressure Testing of Plant Piping and Pipelines

9. SAES-L-350 (30 September, 2003) Construction of Plant Piping

10. SAES-S-010 (31 December 2002) Sanitary Sewers


11/15

As Calculated*

30 mins (min)

Whether piping or tubing, between the root isolation valve and the instrument isolation shall be

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:ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.

Internally FBE

Coated Lines

As Calculated*

30 mins (min)

For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not excee

5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System

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).

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).

Open-Ended

Piping

EXEMPT,

VISUAL EXAM

Drains, vents & piping downstream of pressure relieving devices that discharge directly to the

atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc

REPAIR EXISTING

PIPING

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 press

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

Instrument

Impulse Lines

Air & Inert Gas

(150 psig max)

SERVICE TEST &

Soap Bubble Test

30 mins (min)

Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joint

are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiv

Service tests and final gasket installation.

LP Steam

(60 psig max)

SERVICE TEST

30 mins (min)

Coordinate with system Service tests and construction completion.

See NotesRETESTING

REQMTS

Note:Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined.

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 (chec

low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.

Underground

A) Process Piping

B) Utility Piping

As Calculated

See Notes

A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs.B) P

SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.

ju s ti fi ab le (safet y , bac k-fi ll ed lin e) a 24 h r re cord ed tes t (Ch ar t Record er ) is req d.

Tested to 1.5 times the differential external pressure, but not less than 15 psig.

Weld-Plus-Ends

(SAIC-A-2016)

TEST PRESS

& DURATION

TEST CONSIDERATIONS & NOTES

As Calculated*

30 mins (min)

Piping Line Class List (Hydrotest Spec)lists all new process piping line classes (strength test

required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu o

pressure testmay be performed if requested & approved by SA Insp. Dept. Mgr. Process requesper Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.

Lube & Seal Oil

Systems

See Notes

30 mins (min)

*Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psi

whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely

cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints

*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.

Process

Piping

ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)

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 h

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.

Flare Lines(24" & above)

See Notes

30 mins (min)

Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested

pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3

Vacuum Piping See Notes30 mins (min)

SYSTEM


Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06


Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)

MECH-


Soap Bubble Leak

Test at 5-10 psig

Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus

between the gasket and the seal weld. It shall be examined for leaks using a soap solution.

Existing Plant

Piping

Incl. Tie-Ins

As Calculated*

30 mins (min)

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*.

For revalidation purposes of existing plant piping, the test pressure shall be minimum required by t

Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined a

taken into consideration when calculating the test pressure. In case of flanged tie-in connections,

flange tester is utilized to conduct hydrostatic testing of flange butt weld.

Page 11 of 15


12/15




MECH-


Procedure(Checklist Item D4)

See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be equal

those that the valves were originally purchased to. All resilient (soft) seated isolation

valves shall have zero leakage. See SAIC-L-2042

Vessel & Tank

Trim (Piping)

See Note Test separately (separate package) as required. Exemptions include sight glasses &

other instruments. Strength or Service test associated piping based on service

Note:ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test

All new valves designated for isolation service (as specified by the Proponent) shall

subjected to high pressure hydrostatic seat test prior to installation in line.

Exception See Note

Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a uniqu

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 (Pipin

System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (inte

visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions & follow-up preservation reqmts) &

segregation controlto prevent "mixing valves". Controlled System for Valve Placement exists.

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

New Valves

See Note

Exemption See Note Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt

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

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.

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

6.16 Non Metallic Piping- Such as RTR, Thermoplastic, PVC/UPVC & CPVC shall be tested per SAES-S-070, Section 18.

6.11 Sanitary Sewers- Sanitary sewer systems within buildings shall be tested per reqmts of the Uniform Plumbing Code (UPC). Exceptions t

UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS

Sanitary sewer lines outside of buildingsshall 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.

6.13 Miscellaneous Building Services Piping - Steam & condensate piping outside the jurisdiction of ASME B31.3, heating & cooling water pipi

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

6.9 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).

Fin Fan X-chgr is strength tested (as stamped) in-situprior to final acceptance (new project), & whenever transported.

Heat Exchanger Tube bundles removed from X-chgr (maintenance) get in-situ shell side test per SAES-D-108 prior to return to service

Heater Tube (coil) Assy Hydrostatic test for new, field fabricated heater tube assembly shall be per 32-SAMSS-029.

6.8 Potable Water Systems- Potable water piping inside buildings shall be tested per the reqmts of Uniform Plumbing Code (UPC). Exception

to UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS

Potable water piping outside of buildingsshall be tested per the requirements of SAES-S-040 (SAES-S-070, Section 18).

6.7 Refrigerant Piping Systems- Refrigerant piping serving building air conditioning systems shall be tested according to the requirements of SA

K-001 and the Uniform Mechanical Code (UMC), Section 1520.

6.6 Fire Protection Systems- Pressure test new & existing fire protection systems (SAES-B-017, GI-1781.001).

6.5 Tanks- For new, field fabricated tanks, & existing tanks, hydrostatic testing shall be per 32-SAMSS-006 for large, low pressure welded tan

or 32-SAMSS-005 for atmospheric steel tank, as applicable.

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)

Boilersreceiving 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&Isshall be per test pressure as specified on boiler's safety instruction sheet.

Skid-Mounted

Piping (Vendor)

EXEMPT IF TESTED BY VENDOR

per 01-SAMSS-010

(exceptions noted)

Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure

hydrostatic seat test for flare system valves. Identify & Segregate Early!!!

1. When testing with adjacent Lube oil system piping (no leaks = acceptance).

2. When code repairs are made to skid-mounted piping to correct misalignment,

physical damage or any modifications in-situ, pressure test the affected spools.

Page 12 of 15


13/15

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 witliquid.

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 applicabl

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 term) is same as a hydrostatic leak test (B31.3) or proof test (B31.4)


SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER


Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures

MECH-

SAES-L-150 Pressure Testing Definitions

API 598 & SA Valve Pressure Testing Definitions

Shell (Body Hydrostatic) Test: A pressure test conducted using water or other approved liquid as the test medium a

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.

Pneumatic flushing with dry air (dew point -1C 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.

Mechanical Scrapers: Can be used under the condition that damage to the pipe interior surface shall not occur.

Pressurized Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an alternat

method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems removing trapped liqu

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

more than 810 kPa (115 psi). Safety precaution shall be considered in consultation with Area Loss Prevention Divisio

when this method is used. Repeat PASB until cleanliness is verified by observing the absence of any solids impact on

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 lis

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 du

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. Se

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 -1C and protected against corrosion.Valve Cavities (low points) without drains shall be addressed in the procedure.

SAES-L-350 Appendix A (Cleaning Procedures)

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.Page 13 of 15


14/15



Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 MECH-

TEST WITH ISOLATION AGAINST VALVE SEATS (CALCS) PER SAES-A-004, SECTION 7.3

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 &

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 allowabl

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 #2 (Spec break between systems): CS Class 150 # system (hydrotest at 450 psi, limiting factor = 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).

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 h drotest at 450 si a ainst the valve seat because over ressurization results .

LIMITING FACTOR CALCS (PREVENT OVERPRESSURIZATION & POTENTIAL DAMAGE)

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 flange

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.

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 review, even after 2 errors.

4. Determine piping Pressure ratings as follows in the following code formula based on 90% SMYS (per SA):

Use ASME B31.3 code formula t = PD / 2SE & SA requirement of 90% SMYS values for strength test calcs.Page 14 of 15


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Review Procedure - Pressure Testing for Plant Piping SAIC-A-2001 1-Dec-06 MECH-

Formula for pressure is P = t x 2S(0.9)(E) / D

S = Stress Valuesfrom ASME B31.3 Table A-1 (API 5L Gr. B has a SMYS of 35,000) therefore S = 35,000

t = pipe thickness (nominal less 12.5 % mill tolerance for seamless pipe, less 0.10 for welded plate)

Therefore .375 x 87.5%, t = .328 for both 12 & 24 seamless pipe

P = unknown & E = Quality Factorfrom Table A-1A or Table A-1B (Quality factor for API 5L Seamless Pipe is 1.00),

therefore E = 1.00

D = outside diameterof 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.

Page 15 of 15

Documents

SAIC-A-2001 Rev 3 Review Procedure Pressure Testing (All Applications)