SAIC-A-2015 Rev 2

7/29/2019 SAIC-A-2015 Rev 2

1/9

QC Supervisor Proponent and Others

Name, Sign and Date:

Quality Record Approved:Name, Organization,

Initials and Date:

T&I W itnessed QC Record Reviewed W o

T&I W itnessed QC Record Reviewed W o

Name, Initials and Date:

Performed Inspection Work / Rework May Proceed


QC Record Reviewed Wo

QC Inspector PID Representative


Work is Complete and Ready for Inspection:


T&I Witnessed

REFERENCE

REMARKS:

ATTACHMENTS:Attachment 1 - Pressure Testing Details --------- Attachment 2 - Efficient Practice For Acceptance of Pressure Tests

SAES-L-150,

Para. 7.3

N/A REPASS FAIL

General Requirements ... Use SATR-A-2001 with this checklist

SAES-A-004,

Para. 8.1.2

ITEM

No.

A1

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 and the test pump disconnected. See Attachments 1 & 2.

ACCEPTANCE CRITERIA

A

WORK PE

CONTRACTOR INSPECTION LEVELSAUDI ARAMCO INSPECTION LEVEL

SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER

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

SCHEDULED INSPECTION DATE & TIME MH's SPENTQUANTITY INSP.ACTUAL INSPECTION DATE & TIMESAUDI ARAMCO USE O

LAYOUT DRAWING NUMBER

PLAEQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

Visual Inspection at Test Pressure SAIC-A-2015 1-Dec-06 PIPE-

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Contractor / Third-Party Saudi AramcoConstruction Representative* PMT Representative

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

3. SAES-L-108, Selection of Valves, (30 March, 2005)

REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005)

Attachment 3 - Walkdown Inspection Techniques ----------- Attachment 4 - SAES-L-150 Pressure Testing Application & Insp

A3

SAES-L-150,

Section 7

Plant Piping

A4

Exceptions to Item A3 above, Plant Piping Pressure Testing & Visual

Inspection Requirements. See Attachment 4.

Visual Inspection & Testing meets SAES-L-150 reqmts.

The test pressure shall be maintained for a sufficient time, but shall not be

less than 30* minutes, to determine that there are no leaks.

*Large systems (Plant Piping) can take longer to comp lete.

SAES-L-150,

Para. 7.2

A7

Test Records for each test are entered on a Pressure Test Report Form

2642-ENG. Test duration & Acceptance is shown in Comment section of

report. (Tape has test pressure & test start/finish time)

Remove tape from gage & press into Test Report. Attachment 2.

SAES-A-004,

Para. 8.3

SAES- L-108,

Para. 4.7.6A6

Test procedures, pressures, durations, & leakage acceptance criteria shall

be equal to those that the valves were originally purchased to.

All resilient (soft) seated isolation valves shall have zero leakage.

Valve Testing details are included in separate Procedure

A5

Exceptions to Item A3 above, Pipeline Pressure Testing & Visual

Inspection Requirements. See Attachment 4.

Visual Inspection & Testing meets SAES-L-150 reqmts.

SAES-L-150,

Section 8

Pipelines

A2

All joints including welded shall be left exposed for visual leak detection

during the strength test. External coating & priming of such joints is not

allowed unless approved by the Manager of Inspection Department and the

proponent Organization representative. The pipe itself can be externally

primed and coated to a final coat. See

Attachment 3 (Walkdown Inspection Technique).

7/29/2019 SAIC-A-2015 Rev 2

2/9




Attachment 1 - Pressure Testing Details

Plant Piping Pressure Tests with fluids (Strength & Service tests) are staged with inspection as follows:

A) Preliminary leak check at 50% of test pressure = complete visual to check for leaks. (Contractor)

B) Twenty per cent stage increase thereafter = visual inspection for leaks as evidenced by no noticeable

pressure drop at test gage. Note Filling & Venting Practices & Efficiency

C) Final at 100% of test pressure with test pump disconnected = Complete visual inspection during fullsystem walkdown for leaks by all Inspectors & Witnesses. (SA Inspector Witnesses & Accepts/Rejects test)

See Attachment 2 for Efficiency related to testing and inspection of small systems.

PRESSURE DROPS (GAUGE READINGS) - SURVEILLANCE OF TESTING REPAIR MEETHODS

On return to test manifold & taped gage after preliminary walkdowns, any drop (noticeable) in pressure must be

accounted for by the Inspector. The test does not proceed to a higher pressure until all leaks are repaired

and repaired by approved methods in procedures as follows:

Flanged connections can be retorqued to maximum torque value

Valve stem packings are tightened to stop leaks (Caution: Watch for uneven Packing Gland flange adjustment)

Note: Often Valves arrive from manufacturer with uneven packing gland flanges. Adjustment/repair may be needed.

Threaded joint leaks are repaired (seal welded or reworked)

Weld joint leaks are repaired (approved welding repair procedure)

Weld joint leaks are repaired (approved welding repair procedure)After repairs, pressurize system & repeat the entire walkdown, never assume all leaks are repaired.

SEE ATTACHMENT 3 FOR WALKDOWN TECHNIQUES DURING FINAL PRESSURE TESTING (ACCEPTANCE)

Hydrotest Filling & Venting Practices (Efficiency)1. PRESSURE TESTING IS ALWAYS CRITICAL PATH ON MAJOR PROJECTS

2. COMPANY HAS IDENTIFIED PRESSURE TESTING INEFFICIENCY AS A MAJOR OBSTACLE TO SUCCESS.

3. ROOT CAUSE OF THE INEFFICIENCY IS PRIMARILY POORLY TRAINED TEST CREWS AND INSPECTORS.

4. QUALITY MANAGERS & THEIR INSPECTORS ARE TASKED TO ASSURE BEST & EFFICIENT PRACTICES.

5. WHEN POSSIBLE, MULTIPLE TEST PACKAGES ARE COMBINED INTO ONE TEST. DOCUMENT SET-UP.

6. TEST CREWS SHALL ALLOW ADDITIONAL TIME (EFFECTIVELY VERIFIED) FOR TRAPPED AIR TO VENT.

7. TEST CREWS SHALL PERFORM FINAL FILL SLOWLY AFTER FLUID LEVELS DROP AT OPEN VENTS.

Filling may be done by hand or pump as experience dictates. See Criteria below. Task crews for safety & efficiency.

Trapped air is usually adequately displaced when a solid flow or stream of water is observed coming out of the vent.

8. INSPECTION SHALL EVALUATE EFFICIENCY & ASSURE BEST PRACTICES TO MINIMIZE RETESTS.

BACKGROUND INFORMATION: Thousands of Manhours are lost due to test failures (retest required) when poorly

trained test crews rush during filling. Assure proper venting of air & a slow final fill technique. Efficiency is critical.

Recommendation: Test crews dedicated solely to set-up, filling and other preparation should be utilized.

Training regarding proper filling and venting techniques shall be identified for inefficient test crews who

waste the valuable time of others (Ops, Inspection, SAPMT, PID, etc) when tests fail to hold pressure.

CRITERIA: On initial pressurization, pressure holds AFTER equalization at 50% test pressure. Gauge drops

indicate a leak (acceptable for efficiency) or "inefficient" test crews leaving air in lines (unacceptable).

Note: Gauges that hold pressure at 50% of test pressure almost always pass. Contact SA after lines show a

successful result at 50% initial pressurization stage for efficiency. Communication issue (cell, radio, etc)

Page 2 of 9

7/29/2019 SAIC-A-2015 Rev 2

3/9




Attachment 2 - Efficient Practice For Acceptance of Pressure Tests

EFFICIENT TEST PRACTICE (USE TAPE ON GAUGES)THIS IS FOR ROUTINE PLANT PIPING PRESSURE TESTS (30-MINUTE TESTS) ON SMALL SYSTEMS.

1. PRESSURE TESTING IS ALWAYS CRITICAL PATH ON MAJOR PROJECTS

2. COMPANY HAS IDENTIFIED PRESSURE TESTING INEFFICIENCY AS A MAJOR OBSTACLE TO SUCCESS.3. ROOT CAUSE OF THE INEFFICIENCY IS PRIMARILY POORLY TRAINED TEST CREWS AND INSPECTORS.


5. WHEN POSSIBLE, SAVE TIME DURING PRESSURE TESTING SET-UP & PRODUCTION AS FOLLOWS:

a) Ensure Efficient Test Crew Practices as outlined in Attachment 1. Retrain any crews who are inefficient.

b) Minimize time required for Outside Parties (SAPMT, PID, Proponent, etc) to attend Pressure Testing.

c) Implement an easy to perform and easy to document practice of "tape" application on test gauges.

d) Mimimize time waiting on Project Inspection/SAPMT to ABSOLUTE ZERO as follows for 30-minute tests:

END RESULT WILL BE IMPROVED EFFICIENCY AND LESS TIME ACHIEVING PASSING PRESSURE TESTS.

FOLLOW THESE GENERAL GUIDELINES (DETAILS AS AGREED UPON IN PROJECTS)

1) Notify SA that day (at agreed upon intervals) of the test packages likely to be ready for testing.

2) Notify SA Witness (PMT, PID) exactly when 50% test pressure holds "after equalization". (Cell, Radio)

Technique: QC Inspector has applied a strip of tape (to be later affixed into the test report) on test gauge.

This can be the plain vanilla colored tape approximately 25 mm wide by 50 mm long that allows marking.The QC Inspector or test crew supervisor match marks the test pressure (on equalization at 50%) and

Verifies the test is ready to proceed to the next stage. Company is informed that their witness is needed.

Note: Any pressure drop indicates liklihood of trapped air or leakage as per Attachment 1 (identify the

cause of the pressure drop BEFORE proceeding, checking valve stems, fittings, valve seat leakby, etc ).

Test reaches 100% of test pressure. Allow adequate equalization time. Note exact start time & notify SA*.

At this time, SA (SAPMT, PID, etc) is notified that the test is ready to begin if they are not already present.

*QC Inspector match marks the pressure gauge needle & writes the start time on the tape (30 minute test).

Note: Usually, only a few minutes are required for most walkdowns. At the test conclusion, the time the

test ended is written down on the tape & the Inspector Initials/Dates/Accepts & affixes tape into test report.

COMPANY WITNESS ALSO INITIALS/DATES/ACCEPTS TEST ON THE TAPE AFFIXED INTO TEST REPORT.

PACKAGE CONTROL IS CRITICAL FOR EFFICIENCY. LATER, SIGNATURES ARE OBTAINED EASILY LATER

WHEN HARD TAPE EVIDENCE IS AFFIXED INTO TEST REPORTS. IT ELIMINATES THE NEED FOR 100% SAPRESENCE AT ALL TEST SITES FOR THE ENTIRE TEST DURATION. ALSO, ON VERBAL APPROVAL, AFTER

CONFIDENCE IS OBTAINED THAT TECHNIQUE IS EFFICIENT, START TIMES DO NOT WAIT ON COMPANY.

IN ALL CASES, THE TEST IS TERMINATED WHEN INSPECTORS COMPLETE THEIR EXAMINATIONS.

LARGER SYSTEMS, ESP. WHERE CLIMBING IS REQUIRED, REQUIRED COORDINATED INSP EFFORTS.

PRACTICE IS RECOMMENDED FOR PRESSURE TESTING PROCEDURES & IMMEDIATE IMPLEMENTATION.

Page 3 of 9

7/29/2019 SAIC-A-2015 Rev 2

4/9




Attachment 3 - Walkdown Inspection TechniquesHot Weather Effect & Test Interpretations (Inspector to Note):

1. Test pressures rise steadily and very noticeably due to rise in pipe surface temps during Summer.

2. Test pressure at gage can remain the same and even rise slightly with very small leaks*

* Ensure good walkdown practice. Check valve stems, threads, flanges & low points very closely.

Never assume a test result based on the test gauge. Visually examine the entire pressure boundary methodically.3. Relief valves (set 5% above test pressure) can pop and lower test pressures (nullify test results)

*Efficiency is needed to complete exams as quickly as possible without rushing through inspection.

4. In hot weather, ensure careful bleedoff in inspection presence. Maintain minimum test pressure.

5. Always account for noticeable drops in test pressures. See Potential Leak Sources.

Potential Leak Sources (Inspector to Note):a) Valve leakby and test connection threaded fitting leaks (worn) are the # 1 cause of failed tests*.

* Closed valves used as a test limit are never assumed to be "passing" water. Verify no other leaks

* Closed valves in the test manifold are checked and replaced if they "pass", verify no other leaks

* Threaded pressure hose connections wear out & need frequent replacement. Most common leak.

b) Valve packing leaks are very often found with NO* noticeable test pressure drop (in hot weather)

*The normal test pressure rise due to sun-heated piping is not seen, but negated by packing leak.

c) Flanges with small leaks are hard to find. Check low points by hand*patting & use mirror/light.*A sheet of dry paper can be patted against lowest periphery of the flange. Watch for sharp edges!

d) Threaded joints* are checked closely (leaks are common with inadequate thread engagement).

*Seal welded threaded joints often leak. Best technique is close visual checks with mirror & hand.

e) Socket welds (GTAW & SMAW process) can leak through tiny pores caused by oil contamination.

f) Butt weld leaks are rare & 100% through-wall porosity is often the culprit.

g) Telltale hole leakage (stanchion legs, dummy legs, repads) is thru attachment welds*

* Attachment welds to pressure boundary can burn through & create thru-wall defects that leak

h) Pipe/Fitting manufacturing defects cause thru-wall leaks. There is a variety of common defects*

* Seams, laps, slugs, delaminations, pinholes, tears, shuts and thread defects (torn, flat, etc)

6. Leakage Evidence or questionable leakage (also check gage pressure) is always investigated

Investigate Leakage Evidence (Inspector to Note):

1) Visually attempt to determine the exact source* of leakage evidence (except for obvious leaks)* Never Assume Leakage Evidence is local. The source may be another line (Know the Effects of Gravity).

* Never Assume water present means a test system leak. (Filling Leak Repaired, another source)

* Assess leakage evidence carefully by a detailed visual inspection/observation method:

* Check test gage or have a test crew member return & check the gage for obvious pressure drop

* Never assume because pressure hasn't dropped that a leak does not exist (hot weather effect)

2) Approach the area with caution. Assess the evidence. Is the leak ACTIVE? (Obviously wet or dripping)

3) If yes, wipe the area dry & wait a few seconds (on further leaks, mark the location & move on)

4) If not obvious, but a leak is suspected, wipe area dry & wait 60* seconds. Use Hand/dry paper!

* Ascertain a leakage rate (in drops/minute). Move on and complete the remainder of test.

PROBLEM

5) Test crews often struggle with small leaks & use a pressure gage as their acceptance criteria*.

REASON = INSPECTOR IS LIKELY ACCEPTING TESTS BASED ON GAUGE RESULTS ALONE

SOLUTION = AWARENESS

6) Any Leakage found (rate) on unsuccessful tests is entered in Test Report "Remarks/Comment" Section

Example: Retest OK (no leaks at test pressure) after minor valve packing leaks (2 drops/minute) repaired

NEVER ASS/U/ME A TEST RESULT BASED

ON THE TEST GAUGE ALONE

Page 4 of 9

7/29/2019 SAIC-A-2015 Rev 2

5/9




Attachment 4 - SAES-L-150 Pressure Testing Application & Insp7 Plant Piping Applications

7.1 Unless limited by flanges, valves or other component in the line or specified in paragraph 7.4 below, the

hydrostatic strength test pressure for every section of new constructed line shall produce a hoop stress in the pipe

of 90% of the specified minimum yield strength (SMYS) at the test temperature. The test pressure shall be

calculated based on the pipe nominal wall thickness less the mill tolerance (manufacturer's minus tolerance). The

test pressure shall not be less than the minimum test pressure per ASME B31.3 paragraph 345.4.2.

7.2 Except where specified in 7.4 of this standard, the test pressure shall be maintained for a sufficient time, but

shall not be less than 30 minutes, to determine that there are no leaks. (Item A3 of this Checklist)

7.3 All joints including welded shall be left exposed for visual leak detection during strength test. External coating

and priming of such joints are not allowed unless approved by Manager of Inspection Department and the proponent\

Organization representative. The pipe itself can be externally primed and coated to a final coat.

7.4 Following are specific cases of exemptions to either or both of 7.1 and 7.2 of this standard (Item A4):

7.4.1 Lube and seal oil piping shall be pressure tested with its own fluid. The test pressure shall be 1.5 times the

design pressure or 690 kPa (ga) (100 psig) whichever is the greater. Test duration shall be in accordance with 7.2.

7.4.2 Underground process piping shall be tested prior to backfilling. The test pressure shall be maintained for a

minimum of 2 hours while the joints are inspected for leakage. If for justifiable safety reasons the line must be back-

filled, then the joints shall remain exposed during testing, otherwise the test shall be a 24 hour recorded test. Thetest pressure is in accordance with 7.1.

7.4.3 Flare lines 24-inch NPS and larger* with a design pressure of 517 kPa (ga) (75 psig) or lower may be

pneumatically strength tested in accordance with paragraph 345.5 of ASME B31.3.

* Note: Portions of this line may be smaller than 24" and extend to isolation valves downstream of PZVs, etc

7.4.4 Piping in vacuum service shall be pressure tested to 1.5 times the differential external pressure not less

than 100 kPa (ga) (15 psig). Test duration shall be in accordance with 7.2.

7.4.5 Service test is acceptable for the following per L-150, Para. 7.4.5 (Threaded Joints)a) Plant utility piping in air & inert gas services with designed pressure & equal to less than 035 kPa (ga) (150 psig).

b) Low pressure steam piping designed for 60 psig or less.

INSPECTION SHALL REFER TO SAIC-L-2015 CHECKLIST FOR THREADED JOINTS AS APPLICABLE.

7.5 For revalidation purposes of existing plant piping, test pressure shall be minimum req'd by ASME B31.3.

Actual piping wall thickness and flange rating shall be taken into consideration when calculating the test pressure.8 Pressure Testing of Pipelines

This section defines specific requirements (such as test pressure, duration, etc.) for pressure testing of pipelines.

8.1 Unless limited by flanges or valves in the line, hydrostatic strength test pressure for every section of newly

constructed pipelines shall be calculated to produce a hoop stress of 90% of the SMYS of the pipe material based

on the nominal wall thickness. The test pressure at the lowest point of the pipeline, considering hydrostatic head,

shall not result in a hoop stress greater than the SMYS. Strength test pressure shall be maintained for 2 hours.

8.2 The strength test temperature shall not result in a combined longitudinal stress (calculated based on 0.7 hoop

stress at the test pressure plus temperature stress plus bending stress) exceeding the SMYS.

8.3 Tightness test shall be conducted at 95% of strength test pressure, immediately after completing strength test.

Tightness test pressure shall be maintained as long as req'd for inspector to examine all exposed joints.

A 24-hour recorded tightness testshall be applied when the pipeline is buried or insulated, or is partially

buried or insulated for more than 300 m (1000 ft) or 10% of its total length whichever is less.

11.3 Where pressure variations due to test water temperature changes occur, such as in cross-country pipelines,

thermocouples shall be installed to obtain accurate pipe metal temperature measurements to determine the

acceptance of the pressure test. Chairman of the Piping Standards Committee in Consulting Services Department

shall be consulted for any deviations on the 24 hour pressure chart.

8.4 Existing pipelines if subjected to revalidation pressure testing, the test pressure shall be minimum of 1.25 times

the MAOP for pipelines with 0.6 and 0.72 design factors; and shall be minimum of 1.4 times the MAOP for pipelines

with 0.4 and 0.5 design factors. The actual pipe wall thickness and flange rating shall be taken into consideration

when calculating the test pressure.

For Pipelines, The results of the latest (new) pressure testing shall be documented in the "Safety Instruction Sheet".

PIPELINE PRESSURE VARIATIONS (TEMPERATURE VARIATIONS)

Page 5 of 9

7/29/2019 SAIC-A-2015 Rev 2

6/9

C) Final at 100% of test pressure with test pump disconnected = Complete visual inspection during fullsystem walkdown for leaks by all Inspectors & Witnesses. (SA Inspector Witnesses & Accepts/Rejects test)

See Attachment 2 for Efficiency related to testing and inspection of small systems.

Weld joint leaks are repaired (approved welding repair procedure)

Plant Piping Pressure Tests with fluids (Strength & Service tests) are staged with inspection as follows:

PRESSURE DROPS (GAUGE READINGS) - SURVEILLANCE OF TESTING REPAIR MEETHODS

Valve stem packings are tightened to stop leaks (Caution: Watch for uneven Packing Gland flange adjustment)

Threaded joint leaks are repaired (seal welded or reworked)

Note: Often Valves arrive from manufacturer with uneven packing gland flanges. Adjustment/repair may be needed.

and repaired by approved methods in procedures as follows:

Flanged connections can be retorqued to maximum torque value

A) Preliminary leak check at 50% of test pressure = complete visual to check for leaks. (Contractor)

B) Twenty per cent stage increase thereafter = visual inspection for leaks as evidenced by no noticeable

pressure drop at test gage. Note Filling & Venting Practices & Efficiency

1-Dec-06

Attachment 1 - Pressure Testing Details

PIPE-



Weld joint leaks are repaired (approved welding repair procedure)After repairs, pressurize system & repeat the entire walkdown, never assume all leaks are repaired.

Visual Inspection at Test Pressure

On return to test manifold & taped gage after preliminary walkdowns, any drop (noticeable) in pressure must be

accounted for by the Inspector. The test does not proceed to a higher pressure until all leaks are repaired

SAIC-A-2015

SEE ATTACHMENT 3 FOR WALKDOWN TECHNIQUES DURING FINAL PRESSURE TESTING (ACCEPTANCE)

Recommendation: Test crews dedicated solely to set-up, filling and other preparation should be utilized.

Hydrotest Filling & Venting Practices (Efficiency)1. PRESSURE TESTING IS ALWAYS CRITICAL PATH ON MAJOR PROJECTS

3. ROOT CAUSE OF THE INEFFICIENCY IS PRIMARILY POORLY TRAINED TEST CREWS AND INSPECTORS.

BACKGROUND INFORMATION: Thousands of Manhours are lost due to test failures (retest required) when poorly

Trapped air is usually adequately displaced when a solid flow or stream of water is observed coming out of the vent.

7. TEST CREWS SHALL PERFORM FINAL FILL SLOWLY AFTER FLUID LEVELS DROP AT OPEN VENTS.

Filling may be done by hand or pump as experience dictates. See Criteria below. Task crews for safety & efficiency.

2. COMPANY HAS IDENTIFIED PRESSURE TESTING INEFFICIENCY AS A MAJOR OBSTACLE TO SUCCESS.

8. INSPECTION SHALL EVALUATE EFFICIENCY & ASSURE BEST PRACTICES TO MINIMIZE RETESTS.


5. WHEN POSSIBLE, MULTIPLE TEST PACKAGES ARE COMBINED INTO ONE TEST. DOCUMENT SET-UP.

6. TEST CREWS SHALL ALLOW ADDITIONAL TIME (EFFECTIVELY VERIFIED) FOR TRAPPED AIR TO VENT.

CRITERIA: On initial pressurization, pressure holds AFTER equalization at 50% test pressure. Gauge drops

indicate a leak (acceptable for efficiency) or "inefficient" test crews leaving air in lines (unacceptable).

Note: Gauges that hold pressure at 50% of test pressure almost always pass. Contact SA after lines show a

successful result at 50% initial pressurization stage for efficiency. Communication issue (cell, radio, etc)

waste the valuable time of others (Ops, Inspection, SAPMT, PID, etc) when tests fail to hold pressure.

trained test crews rush during filling. Assure proper venting of air & a slow final fill technique. Efficiency is critical.

Training regarding proper filling and venting techniques shall be identified for inefficient test crews who

Page 6 of 9

7/29/2019 SAIC-A-2015 Rev 2

7/9

LARGER SYSTEMS, ESP. WHERE CLIMBING IS REQUIRED, REQUIRED COORDINATED INSP EFFORTS.

PRACTICE IS RECOMMENDED FOR PRESSURE TESTING PROCEDURES & IMMEDIATE IMPLEMENTATION.

WHEN HARD TAPE EVIDENCE IS AFFIXED INTO TEST REPORTS. IT ELIMINATES THE NEED FOR 100% SAPRESENCE AT ALL TEST SITES FOR THE ENTIRE TEST DURATION. ALSO, ON VERBAL APPROVAL, AFTER

CONFIDENCE IS OBTAINED THAT TECHNIQUE IS EFFICIENT, START TIMES DO NOT WAIT ON COMPANY.

IN ALL CASES, THE TEST IS TERMINATED WHEN INSPECTORS COMPLETE THEIR EXAMINATIONS.


Attachment 2 - Efficient Practice For Acceptance of Pressure Tests

5. WHEN POSSIBLE, SAVE TIME DURING PRESSURE TESTING SET-UP & PRODUCTION AS FOLLOWS:

1-Dec-06 PIPE-

The QC Inspector or test crew supervisor match marks the test pressure (on equalization at 50%) and

Verifies the test is ready to proceed to the next stage. Company is informed that their witness is needed.

Note: Any pressure drop indicates liklihood of trapped air or leakage as per Attachment 1 (identify the

EFFICIENT TEST PRACTICE (USE TAPE ON GAUGES)

3. ROOT CAUSE OF THE INEFFICIENCY IS PRIMARILY POORLY TRAINED TEST CREWS AND INSPECTORS.2. COMPANY HAS IDENTIFIED PRESSURE TESTING INEFFICIENCY AS A MAJOR OBSTACLE TO SUCCESS.



Visual Inspection at Test Pressure SAIC-A-2015

Test reaches 100% of test pressure. Allow adequate equalization time. Note exact start time & notify SA*.

*QC Inspector match marks the pressure gauge needle & writes the start time on the tape (30 minute test).

Note: Usually, only a few minutes are required for most walkdowns. At the test conclusion, the time the

test ended is written down on the tape & the Inspector Initials/Dates/Accepts & affixes tape into test report.

THIS IS FOR ROUTINE PLANT PIPING PRESSURE TESTS (30-MINUTE TESTS) ON SMALL SYSTEMS.

b) Minimize time required for Outside Parties (SAPMT, PID, Proponent, etc) to attend Pressure Testing.

c) Implement an easy to perform and easy to document practice of "tape" application on test gauges.

1. PRESSURE TESTING IS ALWAYS CRITICAL PATH ON MAJOR PROJECTS

a) Ensure Efficient Test Crew Practices as outlined in Attachment 1. Retrain any crews who are inefficient.

cause of the pressure drop BEFORE proceeding, checking valve stems, fittings, valve seat leakby, etc ).

d) Mimimize time waiting on Project Inspection/SAPMT to ABSOLUTE ZERO as follows for 30-minute tests:

1) Notify SA that day (at agreed upon intervals) of the test packages likely to be ready for testing.

FOLLOW THESE GENERAL GUIDELINES (DETAILS AS AGREED UPON IN PROJECTS)

END RESULT WILL BE IMPROVED EFFICIENCY AND LESS TIME ACHIEVING PASSING PRESSURE TESTS.

PACKAGE CONTROL IS CRITICAL FOR EFFICIENCY. LATER, SIGNATURES ARE OBTAINED EASILY LATER

COMPANY WITNESS ALSO INITIALS/DATES/ACCEPTS TEST ON THE TAPE AFFIXED INTO TEST REPORT.

At this time, SA (SAPMT, PID, etc) is notified that the test is ready to begin if they are not already present.

2) Notify SA Witness (PMT, PID) exactly when 50% test pressure holds "after equalization". (Cell, Radio)

Technique: QC Inspector has applied a strip of tape (to be later affixed into the test report) on test gauge.

This can be the plain vanilla colored tape approximately 25 mm wide by 50 mm long that allows marking.

Page 7 of 9

7/29/2019 SAIC-A-2015 Rev 2

8/9

Potential Leak Sources (Inspector to Note):

e) Socket welds (GTAW & SMAW process) can leak through tiny pores caused by oil contamination.

f) Butt weld leaks are rare & 100% through-wall porosity is often the culprit.

g) Telltale hole leakage (stanchion legs, dummy legs, repads) is thru attachment welds*

* Ensure good walkdown practice. Check valve stems, threads, flanges & low points very closely.

Never assume a test result based on the test gauge. Visually examine the entire pressure boundary methodically.3. Relief valves (set 5% above test pressure) can pop and lower test pressures (nullify test results)

1. Test pressures rise steadily and very noticeably due to rise in pipe surface temps during Summer.

5. Always account for noticeable drops in test pressures. See Potential Leak Sources.

* Check test gage or have a test crew member return & check the gage for obvious pressure drop

* Assess leakage evidence carefully by a detailed visual inspection/observation method:

* Never Assume water present means a test system leak. (Filling Leak Repaired, another source)

d) Threaded joints* are checked closely (leaks are common with inadequate thread engagement).

*Seal welded threaded joints often leak. Best technique is close visual checks with mirror & hand.

*Efficiency is needed to complete exams as quickly as possible without rushing through inspection.

4. In hot weather, ensure careful bleedoff in inspection presence. Maintain minimum test pressure.

Visual Inspection at Test Pressure SAIC-A-2015 1-Dec-06

Attachment 3 - Walkdown Inspection Techniques

PIPE-

Hot Weather Effect & Test Interpretations (Inspector to Note):

2. Test pressure at gage can remain the same and even rise slightly with very small leaks*



4) If not obvious, but a leak is suspected, wipe area dry & wait 60* seconds. Use Hand/dry paper!

* Never assume because pressure hasn't dropped that a leak does not exist (hot weather effect)

2) Approach the area with caution. Assess the evidence. Is the leak ACTIVE? (Obviously wet or dripping)

3) If yes, wipe the area dry & wait a few seconds (on further leaks, mark the location & move on)

* Attachment welds to pressure boundary can burn through & create thru-wall defects that leak

Investigate Leakage Evidence (Inspector to Note):

h) Pipe/Fitting manufacturing defects cause thru-wall leaks. There is a variety of common defects*

* Seams, laps, slugs, delaminations, pinholes, tears, shuts and thread defects (torn, flat, etc)

6. Leakage Evidence or questionable leakage (also check gage pressure) is always investigated

NEVER ASS/U/ME A TEST RESULT BASED

ON THE TEST GAUGE ALONE

SOLUTION = AWARENESS

REASON = INSPECTOR IS LIKELY ACCEPTING TESTS BASED ON GAUGE RESULTS ALONE

1) Visually attempt to determine the exact source* of leakage evidence (except for obvious leaks)* Never Assume Leakage Evidence is local. The source may be another line (Know the Effects of Gravity).

* Ascertain a leakage rate (in drops/minute). Move on and complete the remainder of test.

5) Test crews often struggle with small leaks & use a pressure gage as their acceptance criteria*.

PROBLEM

Example: Retest OK (no leaks at test pressure) after minor valve packing leaks (2 drops/minute) repaired

6) Any Leakage found (rate) on unsuccessful tests is entered in Test Report "Remarks/Comment" Section

c) Flanges with small leaks are hard to find. Check low points by hand*patting & use mirror/light.*A sheet of dry paper can be patted against lowest periphery of the flange. Watch for sharp edges!

a) Valve leakby and test connection threaded fitting leaks (worn) are the # 1 cause of failed tests*.

* Closed valves used as a test limit are never assumed to be "passing" water. Verify no other leaks

* Closed valves in the test manifold are checked and replaced if they "pass", verify no other leaks

* Threaded pressure hose connections wear out & need frequent replacement. Most common leak.

b) Valve packing leaks are very often found with NO* noticeable test pressure drop (in hot weather)

*The normal test pressure rise due to sun-heated piping is not seen, but negated by packing leak.

Page 8 of 9

7/29/2019 SAIC-A-2015 Rev 2

9/9

test pressure is in accordance with 7.1.

minimum of 2 hours while the joints are inspected for leakage. If for justifiable safety reasons the line must be back-

filled, then the joints shall remain exposed during testing, otherwise the test shall be a 24 hour recorded test. The

and priming of such joints are not allowed unless approved by Manager of Inspection Department and the proponent\

Organization representative. The pipe itself can be externally primed and coated to a final coat.

7.4 Following are specific cases of exemptions to either or both of 7.1 and 7.2 of this standard (Item A4):

7.4.1 Lube and seal oil piping shall be pressure tested with its own fluid. The test pressure shall be 1.5 times the

PIPELINE PRESSURE VARIATIONS (TEMPERATURE VARIATIONS)

Actual piping wall thickness and flange rating shall be taken into consideration when calculating the test pressure.

when calculating the test pressure.

with 0.4 and 0.5 design factors. The actual pipe wall thickness and flange rating shall be taken into consideration

constructed pipelines shall be calculated to produce a hoop stress of 90% of the SMYS of the pipe material based

on the nominal wall thickness. The test pressure at the lowest point of the pipeline, considering hydrostatic head,

buried or insulated for more than 300 m (1000 ft) or 10% of its total length whichever is less.

the MAOP for pipelines with 0.6 and 0.72 design factors; and shall be minimum of 1.4 times the MAOP for pipelines

8.4 Existing pipelines if subjected to revalidation pressure testing, the test pressure shall be minimum of 1.25 times

For Pipelines, The results of the latest (new) pressure testing shall be documented in the "Safety Instruction Sheet".

A 24-hour recorded tightness testshall be applied when the pipeline is buried or insulated, or is partially

8.3 Tightness test shall be conducted at 95% of strength test pressure, immediately after completing strength test.

Tightness test pressure shall be maintained as long as req'd for inspector to examine all exposed joints.

7.5 For revalidation purposes of existing plant piping, test pressure shall be minimum req'd by ASME B31.3.

INSPECTION SHALL REFER TO SAIC-L-2015 CHECKLIST FOR THREADED JOINTS AS APPLICABLE.

7.4.3 Flare lines 24-inch NPS and larger* with a design pressure of 517 kPa (ga) (75 psig) or lower may be

pneumatically strength tested in accordance with paragraph 345.5 of ASME B31.3.

* Note: Portions of this line may be smaller than 24" and extend to isolation valves downstream of PZVs, etc

This section defines specific requirements (such as test pressure, duration, etc.) for pressure testing of pipelines.

8.1 Unless limited by flanges or valves in the line, hydrostatic strength test pressure for every section of newly

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBERSAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05

7 Plant Piping Applications

hydrostatic strength test pressure for every section of new constructed line shall produce a hoop stress in the pipe

of 90% of the specified minimum yield strength (SMYS) at the test temperature. The test pressure shall be

calculated based on the pipe nominal wall thickness less the mill tolerance (manufacturer's minus tolerance). The

Visual Inspection at Test Pressure SAIC-A-2015 1-Dec-06

Attachment 4 - SAES-L-150 Pressure Testing Application & Insp

PIPE-

than 100 kPa (ga) (15 psig). Test duration shall be in accordance with 7.2.

7.4.5 Service test is acceptable for the following per L-150, Para. 7.4.5 (Threaded Joints)a) Plant utility piping in air & inert gas services with designed pressure & equal to less than 035 kPa (ga) (150 psig).

b) Low pressure steam piping designed for 60 psig or less.

test pressure shall not be less than the minimum test pressure per ASME B31.3 paragraph 345.4.2.

7.1 Unless limited by flanges, valves or other component in the line or specified in paragraph 7.4 below, the

7.2 Except where specified in 7.4 of this standard, the test pressure shall be maintained for a sufficient time, but

shall not be less than 30 minutes, to determine that there are no leaks. (Item A3 of this Checklist)

design pressure or 690 kPa (ga) (100 psig) whichever is the greater. Test duration shall be in accordance with 7.2.

7.4.2 Underground process piping shall be tested prior to backfilling. The test pressure shall be maintained for a

11.3 Where pressure variations due to test water temperature changes occur, such as in cross-country pipelines,

thermocouples shall be installed to obtain accurate pipe metal temperature measurements to determine the

acceptance of the pressure test. Chairman of the Piping Standards Committee in Consulting Services Department

shall be consulted for any deviations on the 24 hour pressure chart.

7.3 All joints including welded shall be left exposed for visual leak detection during strength test. External coating

stress at the test pressure plus temperature stress plus bending stress) exceeding the SMYS.

8.2 The strength test temperature shall not result in a combined longitudinal stress (calculated based on 0.7 hoop

shall not result in a hoop stress greater than the SMYS. Strength test pressure shall be maintained for 2 hours.

8 Pressure Testing of Pipelines

7.4.4 Piping in vacuum service shall be pressure tested to 1.5 times the differential external pressure not less

Page 9 of 9

Documents

SAIC-A-2015 Rev 2