aesa004
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Engineering StandardSAES-A-004 30 March 2005
General Requirements for Pressure esting
Document Responsibility: Inspection Department
Saudi Aramco !es"o# Standards
a$le of %ontents
1 Scope............................................................. 22 Conflicts and Deviations................................. 23 References..................................................... 24 Definitions....................................................... 55 General Requirements................................... 56 Specific Testin Requirement........................ !" Test #reparation........................................... 11! Test #rocedures........................................... 13$ %fter Completion of #ressure Test............... 14
%ppendi& ' ( Sample )orm of Request for*on(Destructive Testin 'n(+ieu of,-drostatic Test........................................... 16
%ppendi& '' ( Sample of S%2642(*G#ressure Test Report )orm......................... 1"
Previous Issue: 30 June 2003 Next Planned Update: 1 pril 200!
Revised para"rap#s are indicated in t#e ri"#t mar"inPa"e 1 o$ 21
Primary contact: Patric% &' (c)#ee on *+3,-.*-
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Document Responsibility: Inspection Department //,,00.
Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
& Sco#e
1.1 This standard defines mandatory general requirements
governing in-situ pressure testing of new and existing pipelines,plant piping and pressure containing process equipment
(hereinafter called equipment). Specific requirements are
covered in the specific S!Ss applica"le to that equipment or
piping system. This standard supplements S#! $%1&s and
other applica"le codes.
1.' The requirements of this standard apply to fieldshop fa"ricated
piping systems and field fa"ricated equipment.
1.% This standard does not cover pressure testing of new, shop
fa"ricated equipment such as vessels, tans, heat exchangers and
sid mounted piping which are purchased in accordance with the
applica"le S#SS.
Exception:
Fin-fan coolers are to be tested in situ in accordance with paragraph 6.4.5.
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Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
1.* This standard applies to pre start-up lea tests normally
conducted "y +perations during start-up, commissioning and
T of the facilities in accordance with approved plantoperating procedures.
1. This standard does not apply to equipment as excluded in section
/.'.
2 %onflicts and !e'iations
'.1 ny conflicts "etween this standard and other applica"le Saudi
ramco !ngineering Standards (S!S&s), #aterials System
Specifications (S#SS&s), Standard 0rawings (SS0&s), or
industry standards, codes, and forms shall "e resolved in writing"y the ompany or $uyer 2epresentative through the #anager,
nspection 0epartment of Saudi ramco, 0hahran.
'.' 0irect all requests to deviate from this standard in writing to the
ompany or $uyer 2epresentative, who shall follow internal
company procedure S!3-%4' and forward such requests to the
#anager, nspection 0epartment of Saudi ramco, 0hahran.
3 References
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Document Responsibility: Inspection Department //,,00.
Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
The selection of material and equipment, and the design, construction,
maintenance, and repair of equipment and facilities required "y this
standard shall comply with the latest edition of the references listed"elow, unless otherwise noted.
%.1 Saudi ramco 2eferences
Saudi ramco !ngineering 3rocedures
SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Reuirement
SAEP-32! "is#osa$ of Waste%ater from &$eaning'
($us)ing' and "e%atering Pi#e$inesand *esse$s
Saudi ramco !ngineering Standards
SAES-A-00+ Safety Instruction S)eet
SAES-A-00! ,ydrostatic esting ($uids and .ay-u#
Procedures
SAES-/-0! (ire Water Systems
SAES-"-001 Ins#ection' Re#airs' A$teration' Rerating
and esting of Eisting PressuredEui#ment
SAES-"-01 Storage an esting and Ins#ection
SAES-,-0 Saudi Aramco Paint and &oating Systems
SAES-4-00 ,eating' *enti$ating and Air-
&onditioning
SAES-.-01 Se$ection of *a$ves
SAES-.-+0 Pressure esting of P$ant Pi#ing and
Pi#e$ines
SAES-.-3+0 &onstruction of P$ant Pi#ing
SAES-5-60 Instrument Air Su##$y Systems
SAES-S-020 Industria$ "rainage and Se%ers
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SAES-S-030 Storm Water "rainage
SAES-S-070 Saudi Aramco Water Systems
SAES-S-080 Saudi Aramco P$umbing &ode
SAES-S-0!0 Insta$$ation of 9ti$ity Pi#ing Systems
Saudi ramco #aterials System Specifications
0-SAMSS-00 (abricated &arbon Stee$ Pi#ing
07-SAMSS-071 *a$ve esting and Ins#ection
Reuirements
32-SAMSS-007 Manufacturing of Pressure *esse$s
32-SAMSS-00+ Manufacturing of Atmos#)eric ans
32-SAMSS-008 Manufacturing of .o% Pressure ans
32-SAMSS-02 Manufacturing of Industria$ Watertube
/oi$ers
32-SAMSS-026 Manufacturing of (ired ,eaters
Saudi ramco 5orm and 0ata Sheet
(orm 2872-E:; Pressure est Re#ort (orm
Saudi ramco 6eneral nstructions
;I-0002
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Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
ASME /3 2 /oi$er and Pressure *esse$ &ode
8ational $oard of $oiler and 3ressure 7essel nspectors
:/ 23 :ationa$ /oard of Ins#ection &ode
4 !efinitions
9ydrostatic Test: pressure test conducted using water or other
approved liquid as the test medium.
3re Start-up ;ea Test: pressure test to ensure tightness of flanged
and threaded
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Strength Test: pressure test at an internal pressure determined in
accordance with this standard and the applica"le ode to verify the
integrity of the piping systems or equipment for service at the designpressure.
System Test: n in-situ pressure test applied to a group of piping and
equipment tested as a system.
3ressure Test 3rocedure. nformation assem"led to ensure all
requirements listed in 6-444'.14' , all referenced Saudi ramco
standards and ndustrial standards are met.
Tightness Test: pressure test to ensure tightness of the piping system
(i.e., no leas in the system) at the test pressure.
5 General Requirements
.1 6eneral nstruction 6-444'.14' >3ressure Testing Safely> shall
"e followed during pressure testing.
.' 3neumatic testing
.'.1 3neumatic testing is not permitted without written
approval of the #anager, nspection 0epartment, unless
specifically allowed "y this standard or the referenced
Saudi ramco S!Ss or S#SSs. This test, whenconducted, shall "e in accordance with 6-444'.14' for
additional safety requirements.
.'.' 3neumatic testing with air of piping systems or equipment
which have "een in flamma"le service shall "e concurred
"y the #anager, ;oss 3revention 0epartment.
.% The effect of the static head of the testing liquid shall "e
considered when determining the effective test pressure of any
elements within a tested system.
.* Test pressures and test durations shall "e "ased on the applica"leramco standards.
. 3rotection from +verpressure
ll systems (piping and equipment) while "eing pressure tested
shall "e protected from "eing overpressured "y the following:
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Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
..1 2elief valve(s) of adequate capacity set to relieve at ?
a"ove the test pressure shall "e installed unless the test
pressure is less than @? S#AS at which time it can "e setat 14? a"ove the test pressure. Si=ing of these relief
valves used for testing shall follow the requirements of 3
23 '4, 3art 1. The relief valve(s) shall "e tested, dated,
and tagged within one wee prior to the pressure test for
new construction pro
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Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
.B.' request for 80T in lieu of pressure testing shall "e
su"mitted for approval as permitted in the specific S!S
listed in Section B "elow. sample form is provided inppendix . This form or an equivalent shall "e processed
prior to 80T.
Commentary Note:
The plant manager will sign the form for existing facilities and theInspection Department Manager will sign for new construction
projects.
./ The requirement for pre start-up lea tests and service tests
during initial start-up and Ts shall "e as follows:
./.1 8ew systems after strength tests and prior to initial start-up:
./.1.1 5or systems with maximum operating pressures
greater than B.@D* #3a (1444 psi), a lea test with
inert gas, followed "y a service test, shall "e
conducted at the maximum operating pressure of
the piping system. +il flowlines, trunlines,
testlines and water in
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Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
./.'.1 5or systems with maximum operating pressures
greater than B.@D* #3a (1444 psi) which are in
hydrogen service or in sour service with hydrogensulfide concentrations higher than 4.1 mole ?:
./.'.1.1 pre start-up lea test with inert gas
shall "e conducted after ma
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.@ f the drop in am"ient temperature may cause the test medium
to free=e during the test, appropriate precautionary measures
must "e taen to protect the equipment or piping systems.
( S#ecific esting Requirement
This section specifies in details which piping or equipment that shall "e
pressure tested and provides the specific applica"le standard. t also
defines any specific exemptions.
B.1 3lant 3iping
3ressure testing of plant piping shall "e in accordance with
S!S-;-14.
B.' ross-ountry 3ipelines
Pressure testing of cross country pipelines shall be in accordance
of SAES-L-150.
B.% 3ressure 7essels
B.%.1 9ydrostatic testing for new vessels (shop or field
fa"ricated) shall "e conducted as follows:
S#! Section 7, 01 to S#SS-44*, 3aragraph
1B.%[email protected].
S#! Section 7, 0' to S#SS-44*, 3aragraph
1B.%.@.'.
B.%.' 9ydrostatic testing for existing vessels shall "e conducted
per S!S-0-44@, 3aragraph 14.1.
B.%.% 3neumatic test, when approved (refer to paragraph .'),
shall "e conducted per E6-144 of S#! S! 7 01, or
T-* of S#! S! 7 0', whichever is applica"le.
B.* 9eat Transfer !quipment
B.*.1 9ydrostatic tests for existing equipment shall "e in
accordance with S!S-0-44@.
B.*.' 5or pneumatic testing, refer to paragraph B.%.'.
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Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
B.*.% 9ydrostatic testing of new, field fa"ricated "oilers shall "e
in accordance with %'-S#SS-4'1. 5or pressure testing
after repair or alteration, refer to S!S-0-44@ and8ational $oard nspection ode, 8$-'%. 9ydrostatic test
during Ts shall "e in accordance with the test pressure
as specified on "oiler&s safety instruction sheet.
9ydrostatic test for new, field fa"ricated heater tu"e
assem"ly shall "e in accordance with %'-S#SS-4'D.
B.*.* Tu"e "undles which have "een removed from the
exchanger shell for maintenance purposes, shall "e
su"
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Issue Date: 30 (arc# 200
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B.@ 3ota"le Fater Systems
3ota"le water piping inside "uildings shall "e tested in
accordance with the requirements of the Eniform 3lum"ingode (E3). !xceptions to E3 requirements are listed in
S!S-S-4B4.
3ota"le water piping outside of "uildings shall "e tested in
accordance with the requirements of S!S-S-4*4.
B.D Etility 3iping Systems
Etility piping systems, including irrigation piping and water
distri"ution mains, shall "e tested in accordance with S!S-S-
4/4.B.14 ndustrial 0rainage and Sewers
ndustrial drainage and sewers shall "e tested in accordance
with S!S-S-4'4.
B.11 Sanitary Sewers
Sanitary sewer systems within "uildings shall "e tested per
requirements of the Eniform 3lum"ing ode (E3). !xceptions
to E3 requirements are listed in S!S-S-4B4.
Sanitary sewer lines outside of "uildings shall "e tested inaccordance with S!S-S-4/4.
B.1' Storm Fater 0rainage Systems
Storm water drainage systems shall "e tested per S!S-S-4%4.
B.1% #iscellaneous $uilding Services 3iping
Steam and condensate piping outside the
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7alves shall "e tested in accordance with S!S-;-14@.
B.1B 8on #etallic 3iping
8on metallic piping such as 2T2, Thermoplastic, 37E37
and 37 shall "e tested in accordance S!S-S-4/4.
) est Pre#aration
/.1 Site 3reparation
/.1.1 n approved test procedure shall "e availa"le at the site
prior to commencing any pressure testing activities.
/.1.' 8ew piping systems shall "e cleaned in accordance with
S!S-;-%4./.1.% Soft seated valves and control valves shall not "e installed
until after the lines have "een thoroughly flushed.
/.1.* omponents in new piping systems which interfere with
filling, venting, draining or flushing shall not "e installed
until after line flushing and pressure testing are completed.
These include orifice plates, flow no==les, sight glasses,
venturies, positive displacement and tur"ine meters and
other in-line equipment.
/.1. 3ressure gauges and pressure recorders shall "e cali"rated
"efore the tests.
a) The cali"ration interval shall not exceed one (1)
month. ali"ration certificates shall "e made
availa"le to nspection personnel prior to
commencement of the pressure test. Sticers shall "e
applied indicating the latest cali"ration date.
") ll gauges shall have a range such that the test
pressure is within %4 to @4? of the full range.c) minimum of two pressure gauges are required for
the test system. +ne pressure gage shall "e on the test
manifold and the other(s) on the test system. Their
accuracy shall "e within ? of one another.
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d) Fhen large systems are tested, nspection personnel
will determine the need for additional gauges.
e) 2ecording gauges shall "e used where it is necessaryto eep a permanent record, e.g., when the test
duration exceeds four hours, or otherwise as required
"y this standard.
/.1.B !xpansion
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3addle "linds or spectacle "linds shall "e used to isolate the test
sections. They shall "e the same class rating of the system or
may "e fa"ricated "ased on appropriate calculations. Fhen thisis not practical, closed "loc valves (gate, glo"e, plug, "all) may
"e used to isolate equipment or piping sections (provided the
valves are not passing, otherwise the spectacle plate"lind shall
"e installed in the closed position). f closed "loc valves are
used in lieu of "linds, provisions shall "e made to ensure no
overpressure can occur in the system that is not "eing tested, due
to possi"le lea through the valves.
Fhen a "loc valve is used for isolating test sections, the
differential pressure across the valve seat shall not exceed theseat test pressure during pressure testing and shall not exceed
the rated seat pressure during tightness test. $oth sides of this
valve shall "e protected "y relief valves during the test.
/.* 7ents and 0rains
/.*.1 7ents shall "e provided at all high points in the tested
system as needed.
/.*.' !xcluding scrapa"le, su"marine and "uried pipelines,
drains shall "e provided at all low points in the system and
immediately a"ove chec valves in vertical lines.
/.*.% Enless the chec valve has a "y-pass valve, the disc of the
chec valve shall "e removed, and securely attached to the
outside of the chec valve prior to the pressure test.
/. Temporary onnections and Supports
/..1 Temporary connections shall "e provided for de-
pressuri=ing and draining of the system to the sewer or
disposal area.
/..' Temporary supports shall "e installed prior to hydrostatictesting, and flushing of the piping if they were determined
to "e required per S!S-;-14. These supports shall not
"e removed until after the system has "een fully drained.
The structural support system for staced equipment shall
"e verified for hydrostatic loads prior to testing.
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* est Procedures
@.1 The test procedures shall "e conducted in accordance with the
applica"le code. n addition, the following requirements shallapply.
@.1.1 5illing and pressuri=ing shall "e done on the upstream side
of chec valves in the system. The test fluid shall "e
inSafety nstruction Sheet> per
S!S--44.
+ After %om#letion of Pressure est
fter pressure testing has "een successfully completed and approved
"y the +wner&s nspector, the following operations shall "e made.
D.1 0raining of Test 5luid
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2elease of pressure and draining shall "e done on the
downstream side of chec valves. ll vents shall "e opened
"efore draining to facilitate drainage and to prevent formation ofa vacuum. 8o test fluid shall remain in low spots.
D.' 0isposal of Test 5luid
The test fluid shall "e disposed in accordance with S!3-%'/ or
as directed "y the +wner.
D.% Test 7ents and 0rains
7ents and drains used only for the pressure test shall "e plugged,
seal welded and penetrant tested.
D.* 2emoval and 2econnection of omponents
ll temporary items installed for testing purposes (e.g.,
manifolds, valves, "linds, spacers, supports) shall "e removed.
tems that were removed from testing shall "e reinstalled.
tems, such as instrument air tu"ing, chec valve discs which
were disconnected "efore testing shall "e reconnected.
solation valves closed for the test purposes and that are required
to "e in the open position for process reasons shall "e opened. f
the valve cavity has a drain, the cavity shall "e drained.
Re'ision Summar,3/ 0arc 2//5 0aor revision.
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A##endi .. / Sam#le of SA 2(42-E1G Pressure est Re#ort orm
SE0 2#+ 32!SSE2! T!ST 2!3+2T
/UDI R(4 2-.2,N) 503607
2eference 0etails:
Plant Name: 8888888888888888888888888888Plant No': 888888888889I No': 888888888888888 Proect Name:
88888888888888888888888
Responsible Inspection Unit: 88888888888888 uipment Description: 88888888888888888888888 ;ocation o$ &est:
8888888888888888888
/ystem No': 88888888888888888 Purc#ase6
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Issue Date: 30 (arc# 200
Next Planned Update: 1 pril 200! )eneral Reuirements $or Pressure &estin"
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III3ressure Test 2esults: ccepted: Reected:
Inspectors Name: 8888888888888888888888 /i"nature: 88888888888888888888888 9ad"e No': 888888888888 Date:
888868888886888888
@ield /upervisor Name: 88888888888888888 /i"nature: 88888888888888888888888 9ad"e No': 888888888888 Date:
888868888886888888
omments:
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