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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05

4) Sample Test Package System ID & Status Report (Database). This is mandatory on large projects. Procedures shall detail Organizational C

responsibilities for test packages & have provisions for "lost packages" & other system controls for test packages from package design through

system completion (MCC) and the QC certification process including turnover of records.

6) Test Package Format (Organization of Sections) shall be in the most effic ient manner possible to eliminate package size and yet contain all

applicable/important test information and documents needed for safe and correct system pressure testing. Copies of any procedures (Pressure

Leak Test, Reinstatement) shall only be provided with test packages on review for initial approval by Company. Procedure copies (Pressure Te

GI-2.102, etc) shall be kept at test sites (test manifolds) with associated Safe Work Permits. Combining QC forms is encouraged. SATR use is

required or alternatively, QC test reports shall contain SATR elements. Increase efficiency & eliminate waste.

5) Pressure Test Matrix is a modified line list showing all systems and proposed pressure test design for SA approval. Reduce review time

significantly & improve efficiency by performing a close review of Pressure Test Matrix & associated system information early on in major proje

"Critical Path" to MCC is nearly always Test Package Completion. Delays are often due to inefficiency, poor organization and planning, a lack o

dedicated manpower solely for Pressure Test Package development, coordination, clearance, & inadequate test planning based on a system

approach.

A2

A4

ACCEPTANCE CRITERIA REFERENCE PASS

A Test Package Database & Format (Minimum Requirements)

Features of the database shall be compatible (linked = preference) with

other SAEP-1160 required databases such as Welding & NDT to allow

efficient test package clearance control practices on a system or line

designation basis.

Note: NDT & other special processes (PWHT, PMI, Coatings, etc)

frequently hold up test package issuance. To improve efficiency, link

databases to improve package coordination, prevent rework andretesting, and identify/target outstanding special process work

SAEP-1160,

Para. 5.1,

Para. 5.2

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

NOTES: 1) SAEP-1160 Section 8 details Minimum Test Package Requirements for Projects (Plant Piping, Pipelines, Equipment). Usage of SA

1160 is mandatory when referenced by Sch Q for contracts with December 2005 cut-off dates and later.

Pressure Test Matrix (Design) uses a modified system line list and

contains specific proposed test information such as system names, line

numbers, testing design data (system class, design/test pressures

proposed), proposed test medium, test type (Hydrostatic or Pneumatic

strength test, Service Test, Bubble Leak Test, flushing requirements,

proposed Lay-up, special considerations/treatments, Chemical cleaning,

mechanical cleaning, internal FBE coating, and other pressure testdesign considerations within Remarks section. Submit this Matrix

along with a Sample Package

SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER

MECH-

FAIL N/A RE-INSP

EQPT CODE SYSTEM ID. PLANT NO.

TRAVEL

EQUIPMENT DESCRIPTION

Review of Test Package Preparation

(Content, Format & Database)SAIC-A-2003 1-Dec-06

LAYOUT DRAWING NUMBER

EQUIPMENT ID NUMBER(S)

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

SAUDI ARAMCO USE ONLYSAUDI ARAMCO ACTIVITY NUMBER

EC / PMCC / MCC NO.REV. NO. PURCHASE ORDER NUMBER

WORK PERMIT RE

CONTRACTOR INSPECTION LEVELSAUDI ARAMCO INSPECTION LEVEL

SAUDI ARAMCO TIP NUMBER

2) Pressure Test Packages are (an integral part of) Test Procedures (See SAES-A-004 definition). Both Contract Sch Q & SAEP-1160 require

Pressure Testing Procedure, along with other procedures & a Test Package for effective/safe pressure testing work control.

3) Submit a single multiple document package as follows (30 days before the start of work per Sch Q) for Company approval:

a) Three mandatory Pressure Test Procedures (as applicable) can be combined into one (Hydrotest, Pneumatic Test, Bubble Leak Test).

b) Sample Test package with applicable QC records, Forms (per Attachment 1 of the Checklist and as listed below).

c) A Re-instatement Procedure and Checklist (Utilize SAIC-A-2006 & SATR-A-2011 or QC forms meeting SATR minimum content).

d) Pressure Test System Matrix (Modified Piping Design Line Index) per checklist as listed below.

e) Pressure Test Package Database - Sample Status Report (per checklist as l isted below).

A1

ITEM

No.

A3

Test Package Data Tracking System (Database) utilizes an elecronic

format acceptable to Company and demonstates effective Test package

tracking (system/line basis). Database is maintained & kept current &

available at all times for Saudi Aramco review.

Submit a sample "Database Status Report for Test Pkgs"

Test Package Minimum Content is per Attachment 1

Note: This checklist details SAEP-1160 specific requirements

SAEP-1160,

Section 8

SAEP-1160,

Para. 5.1,

Para. 5.2

SAEP-1160,

Para. 5.1,

Para. 5.2

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DATE APPROVED QR NUMBER



SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER

FAIL N/A


(Content, Format & Database)SAIC-A-2003 1-Dec-06 MECH-

ITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS

SAEP-1160,

Section 8

RE-INSP D

A5

Individual Test Packages consist of multiple sections:A) Flow Chart per Attachment 2 with an Index Page (Pkg Contents)

B) Pre-Pressure Test (Punch List) Section with Checklists & Forms

C) QC/NDE/Special Process Documentation (SAEP-1160 Database)

D) Pressure Test Section (SIS, system info, test/calibration reports)

E) System Cleanliness & Lay-Up & associated documentation

F) Re-Instatement Procedure with Final Inspection (QC Certified)

Six sections above can be broken down into additional sections as

outlined in Pressure Testing Procedure & Sample Test Pkg.

SAEP-1160,

Section 8

A7Index Page denotes Package Content and has specific signoffs for

Quality Control/Assurance. This can be indexed by Section.

SAEP-1160,

Section 8

A6Test Package Flow Chart (Attachment 2) denotes responsible

agencies for tracking & confirmation of various inspection reqmts.

B Pre-Pressure Test Checklist (or Punchlist) Section contains the following:

B1

Pre-Pressure Test Checklist (Punchlist) Section meets the following

requirements for specific content and field instruction:

A) Specific SAIC-A-2010 - Pre-Pressure Test Checklist (Punchlist) for

On-Plot Piping

B) SATR-A-2007 - Pre-Pressure Test Check List (QC Form)

Checklist shall cover all anticipated workscope items & provide

adequate field instruction. Spec Check usage is recommended.

SAEP-1160,

Section 8

B2

P&ID & Isometric Drawings including a bill of materials/specs.

An Index of applicable drawings is included in the test package.

Reference all Line List numbers & corresponding dwg numbers

SAEP-1160,

Section 8

C QA/QC Documentation Section contains the following (as applicable)

C1

Weld Inspection Summary Sheet (Elements per SATR-W-2008)

Note 1: This can be a single Sheet Database including all special

process work in strict accordance with SAEP-1160 Sect. 6 Tables

Note 2: Limited scopes (500 or less welds/project) are exempt and can

use a Company approved hard copy tracking system.

SAEP-1160,Section 5.1

C2Detailed Weld Map (Isos for Plant Piping, pipelines use isos or sketch

with detailed notes and legend as approved by Company)

SAEP-1160,

Section 8

SAEP-1160,

Section 8

C3NDE Records (MT, PT, RT, UT) showing extent, sequence on NDE and

selection meeting project specifications

SAEP-1160,

Section 8

C5Isolation Valve Test Certificates are available & utilize a uniqueIdentification number whenever valves are field tested before their

installation into the line for pressure testing.

SAEP-1160,

Section 8

C4

As-Built drawings as applicable to the workscope.

Note 1: Test package SHALL show the actual system under test. Ensure

piping modifications/revisions/dimensional changes are corrected by

hand (red ink is preferable) on isos/sketches. Note 2:

Corrections made by hand are acceptable (Initial & date).

Note 3: "Provide As-Built drawings" can be listed as a "B" item

C6 Flange Joint Assembly Inspection Report (SATR-L-2001).SAEP-1160,

Section 8

SAEP-1160,

Section 8

C7 Internal Cleanliness / Flushing Report (SATR-A-2008)SAEP-1160,

Section 8

C8Checklists for test preparation and Test Equipment verification

(SAIC-A-2009)

SAEP-1160,

Section 8

C8 Verification of System Readiness for Testing (SAIC-A-2004)

C9 Pressure Test Report Form (SATR-A-2001)SAEP-1160,

Section 8

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2

SAEP-1160,

Section 8

C10

Calibration or Test certificates for the following test instruments as

applicable: (Equivalent approved test reports are acceptable)

a. Pressure gage and recorders (SATR-A-2002/2004)

b. Temperature gage and recorders (SATR-A-2003/2005)

c. Test Relief Valve/s (SATR-A-2006)

d. Test Manifold (SATR-A-2001)

e. Water Analysis (test medium) - (SATR-A-2014)

SAEP-1160,

Section 8

E System Lay-up

C11 Reinstatement Procedure QC form & Instructions.

E1 System Lay-Up Certificate Form (SATR-A-2009)SAEP-1160,

Section 8

F Re-instatement and/or Final Assembly

REMARKS:

REFERENCE DOCUMENTS:

1. SAEP-1160 - Process Controls for Capital Projects (June 7, 2006)

F1

Final Punch List (By the Contractor)

a. SAIC-L-2022 &

b. SATR-A-2011

SAEP-1160,

Section 8

2. Schedule Q Pro Forma Contract (Contract Edition)

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative

Name, Initials and Date:

Work is Complete and Ready for Inspection:


T&I Witnessed QC Record Reviewed W or

QC Inspector PID Representative


Performed Inspection Work / Rework May Proceed



QC Supervisor Proponent and Others

Name, Sign and Date:

Quality Record Approved:Name, Organization,

Initials and Date:


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

31-Dec-05


N/A


(Content, Format & Database)SAIC-A-2003 1-Dec-06 MECH


REITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER



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

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

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Attachment 2 -- TEST PACKAGE FLOW CHART

Test Package (or Test System) No

Test Pack

Preparation Engineering Contractor QC

31-Dec-05

Pre-Test

Punch

Listing

(NOTE: Use form SATR-A-2007)

Construction Contractor QC

S. Aramco

Pre-Test

Punch

ListingSAPMT PID Proponent

(By Request)

Clear 'A'

Items Construction Contractor QC

Clear

S. Aramco

'A' ItemsConstruction Contractor QC SAPMT PID

Flushing &

Cleanliness Construction Contractor QC SAPMT PID Proponent

(By Request)

Proponent

(By Request)

Pressure

Testing Construction Contractor QC SAPMT PID Proponent

Construction Contractor QC SAPMT

System

Lay-Up Construction Contractor QC SAPMT PID

S. Aramco

Final Insp

for MCCSAPMT PID Proponent

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED

Reinstate

System

Final Insp

(Contractor)

QR NUMBER



Page 5 of 9

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C6 Flange Joint Assembly Inspection Report (SATR-L-2001).SAEP-1160,

Section 8

C5Isolation Valve Test Certificates are available & utilize a uniqueIdentification number whenever valves are field tested before their

installation into the line for pressure testing.

SAEP-1160,

Section 8

QA/QC Documentation Section contains the following (as applicable)C

C1

Weld Inspection Summary Sheet (Elements per SATR-W-2008)

Note 1: This can be a single Sheet Database including all special

process work in strict accordance with SAEP-1160 Sect. 6 Tables

Note 2: Limited scopes (500 or less welds/project) are exempt and can

use a Company approved hard copy tracking system.

SAEP-1160,Section 5.1

C2Detailed Weld Map (Isos for Plant Piping, pipelines use isos or sketch

with detailed notes and legend as approved by Company)

SAEP-1160,

Section 8

C3NDE Records (MT, PT, RT, UT) showing extent, sequence on NDE and

selection meeting project specifications

SAEP-1160,

Section 8

C4

As-Built drawings as applicable to the workscope.

Note 1: Test package SHALL show the actual system under test. Ensure

piping modifications/revisions/dimensional changes are corrected by

hand (red ink is preferable) on isos/sketches. Note 2:

Corrections made by hand are acceptable (Initial & date).

Note 3: "Provide As-Built drawings" can be listed as a "B" item

SAEP-1160,

Section 8

B2

P&ID & Isometric Drawings including a bill of materials/specs.

An Index of applicable drawings is included in the test package.

Reference all Line List numbers & corresponding dwg numbers

SAEP-1160,

Section 8

C9 Pressure Test Report Form (SATR-A-2001)SAEP-1160,

Section 8

A7Index Page denotes Package Content and has specific signoffs for

Quality Control/Assurance. This can be indexed by Section.

SAEP-1160,

Section 8

B1

Pre-Pressure Test Checklist (Punchlist) Section meets the following

requirements for specific content and field instruction:

A) Specific SAIC-A-2010 - Pre-Pressure Test Checklist (Punchlist) for

On-Plot Piping

B) SATR-A-2007 - Pre-Pressure Test Check List (QC Form)

Checklist shall cover all anticipated workscope items & provide

adequate field instruction. Spec Check usage is recommended.

SAEP-1160,

Section 8

B Pre-Pressure Test Checklist (or Punchlist) Section contains the following:

A6Test Package Flow Chart (Attachment 2) denotes responsible

agencies for tracking & confirmation of various inspection reqmts.

SAEP-1160,

Section 8

C8 Verification of System Readiness for Testing (SAIC-A-2004)SAEP-1160,

Section 8

C7

SAEP-1160,

Section 8

ITEM

No.ACCEPTANCE CRITERIA FAIL N/AREFERENCE PASS RE-INSP D

A5

C8Checklists for test preparation and Test Equipment verification

(SAIC-A-2009)





Individual Test Packages consist of multiple sections:A) Flow Chart per Attachment 2 with an Index Page (Pkg Contents)

B) Pre-Pressure Test (Punch List) Section with Checklists & Forms

C) QC/NDE/Special Process Documentation (SAEP-1160 Database)

D) Pressure Test Section (SIS, system info, test/calibration reports)

E) System Cleanliness & Lay-Up & associated documentation

F) Re-Instatement Procedure with Final Inspection (QC Certified)

Six sections above can be broken down into additional sections as

outlined in Pressure Testing Procedure & Sample Test Pkg.

SAEP-1160,

Section 8

Internal Cleanliness / Flushing Report (SATR-A-2008)SAEP-1160,

Section 8

Page 6 of 9

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ITEM

No.ACCEPTANCE CRITERIA FAIL N/AREFERENCE PASS RE




(Content, Format & Database)SAIC-A-2003 1-Dec-06 MECH

C10

Calibration or Test certificates for the following test instruments as

applicable: (Equivalent approved test reports are acceptable)

a. Pressure gage and recorders (SATR-A-2002/2004)

b. Temperature gage and recorders (SATR-A-2003/2005)

c. Test Relief Valve/s (SATR-A-2006)

d. Test Manifold (SATR-A-2001)

e. Water Analysis (test medium) - (SATR-A-2014)

SAEP-1160,

Section 8

SAEP-1160,

Section 8

F1

Final Punch List (By the Contractor)

a. SAIC-L-2022 &

b. SATR-A-2011

SAEP-1160,

Section 8

System Lay-Up Certificate Form (SATR-A-2009)SAEP-1160,

Section 8

C11 Reinstatement Procedure QC form & Instructions.

REFERENCE DOCUMENTS:

1. SAEP-1160 - Process Controls for Capital Projects (June 7, 2006)

2. Schedule Q Pro Forma Contract (Contract Edition)

E1


QC Record Reviewed Wor

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

QC Supervisor Proponent and Others

Name, Sign and Date:

Quality Record Approved:Name, Organization,

Initials and Date:



Performed Inspection Work / Rework May Proceed


QC Inspector PID Representative


Work is Complete and Ready for Inspection:


T&I Witnessed

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative

E System Lay-up

REMARKS:

F Re-instatement and/or Final Assembly

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

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


(Content, Format & Database)MECH-SAIC-A-2003 1-Dec-06

Page 8 of 9

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(Content, Format & Database)MECH-SAIC-A-2003 1-Dec-06

Attachment 2 -- TEST PACKAGE FLOW CHART

Test Package (or Test System) No

Flushing &

Cleanliness PID Proponent

(By Request)

PID

Test Pack

Preparation Engineering Contractor QC

Pre-Test

Punch

ListingConstruction Contractor QC

Construction Contractor QC SAPMT

PIDContractor QC SAPMT Proponent

System

Lay-Up Construction Contractor QC SAPMT PID Proponent

(By Request)

Pressure

Testing Construction

S. Aramco

Final Insp

for MCCSAPMT PID

Reinstate

System

Final Insp

(Contractor)Construction Contractor QC SAPMT

Proponent

Clear

S. Aramco

'A' ItemsConstruction Contractor QC SAPMT

Clear 'A'

Items Construction Contractor QC

S. Aramco

Pre-Test

Punch

ListingSAPMT PID Proponent

(By Request)

(NOTE: Use form SATR-A-2007)

Page 9 of 9

Documents

SAIC-A-2003 Rev 2