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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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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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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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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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..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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.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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./.'.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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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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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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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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