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A4

Effective Corrosion Control & Preservation Measures

Inspection Coverage and Responsibilities (Package Clearance)

Clearly detailed provisions for Retesting after reinstatement Evaluations

by Inspection. Construction related provisions.

SAES-L-350,

Para. 17.2

Welding of attachment welds for non-pressure containing parts such as

wear pads.info only

A10 Coating & insulation, steam tracing & final inspection (Clearances) info only

A11Support Installations & Reinspection of Systems for Plant Piping

Alignment, clearances, fabrication tolerances and workmanship. info only

Instrument impulse l ine testing and completion (tested with sytem) info only

A6

A8 Installation of valves not tested in the line (field test and cert req'd) info only

A9

SAES-L-350,

Para. 17.2 &

SAES-A-004,

Section 9

Specifically, Procedure shall detail PLAN or STRATEGY to reach

"SYSTEM" COMPLETION (Quality Certification) as efficiently as

possible while accomplishing critical goals of:

A) Effective Water Removal, Disposal & Lay-Up (Post Test)

No test fluid shall remain in low spots. Specifically, valve cavities.

B) Test Vents and Drains (plugged, seal welded & PT'd)

C) Removal & reconnection of components

All temporary items installed for testing (e.g., manifolds, valves,

blinds, spacers, supports) shall be removed. Valves Installed. Items that

were removed from testing shall be reinstalled. Items, such as

instrument air tubing, check valve discs reconnected (witnessed). Valve

line-up & gasket installations meet specifications.

A7

Completion of open-ended Piping such as drains, vents and piping

downstream of pressure relieving devices that discharge directly to the

atmosphere (excluded from in-situ pressure testing).

info only

N/A

MH's SPENT TRAVEL TIME

PASS

General Requirements (Complete SATR-A-2007, listed as Attachment 5 & use SATR-A-2011 & SATR-A-6133)

SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED

CONTRACTOR / SUBCONTRACTOR

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 1-Dec-06 Piping-

QR NUMBER

PROJECT TITLE WBS / BI / JO NUMBER

PLANT NO.EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.

LAYOUT DRAWING NUMBER

SCHEDULED INSPECTION DATE & TIME

REV. NO. PURCHASE ORDER NUMBER

FAIL

SAUDI ARAMCO INSPECTION LEVEL

ITEM

No.

CONTRACTOR INSPECTION LEVEL

A1

Post Test Reinstatement Procedure & Checklist is required to

be developed in accordance with & as part of pressure testing.

This is a pressure testing procedure & test package component to be

developed during package creation as based on workscope & specific

"system" requirements.

Comm ent: A standard post-test checklist does not provid e a

procedu re for reinstatement. A detailed proc edure to give clear

field direction along with a checklist for this activ ity sh all be

subm itted before the start of work.

SAEP-1160,

Section 8

Note

Note: The Pre-Test Checklist & Attachments 1-4 were left in this

checklist. Many apply to post-test requirements and shall help Contractor

develop this procedure & checklist. Further assistance can be provided

upon request.

info only

A2

Inspection strategies & plans shall be prepared and agreed on prior to

commencing of testing. This is in common with Pipelines.

Pipelines simply follow their reinstatement procedure.

SAES-L-350,

Para. 17.2

A3

QUANTITY INSP.

SAUDI ARAMCO USE ONLYWORK PERMIT REQUIRED?SAUDI ARAMCO ACTIVITY NUMBER

RE-INSP DATEREFERENCE

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

A

ACTUAL INSPECTION DATE & TIME

SAUDI ARAMCO TIP NUMBER

EC / PMCC / MCC NO.

ACCEPTANCE CRITERIA

A5 Seal welding of threaded connections and NDT associated info only

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SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 1-Dec-06 Piping-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE

C SAIC-A-2010 Checklist (Reinstatement Procedure & Checklist item required (when bold.

SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS (See E-Library, Folder 25)

C1

All joints (flange, threaded, welded or mechanical seals) are left exposed

for visual leak detection during the strength test.

A) External coating & priming of joints is allowed only if approved by Insp

Dept Mgr & proponent Organization Representative.

B) The pipe itself can be externally primed & coated to a final coat.

SAES-L-150,

Para. 7.3

System

clearance

(Controls)

Final Coating

& Insulation

Protection

Controls

Plan/Strategy

C2All permanent flange jointswere inspected, gasket mat'l verified &

properly torqued. (Review Flange joint report, SAIC-L-2014)

SAES-L-450,

Para. 9.4

Final & Perm

Gasket Install

Plug, cap seal

welding, PT

C3Drains shall be provided at all low points of the piping system.

Note: Exceptions are submarine & buried* pipelines (*pump-outs)

SAES-L-150,

Para. 6.2

SAES-L-150,

Para. 6.3

Water removal

Lay-up

C4Vents and drain valves, both temporary and permanent, conforms with

the piping class or rating. ( Refer SAES-L-108)

SAES-L-105,

Para. 5.9

Tolerances,

specs

C6Expansion joints and spring hangers or spring supports are provided with

temporary restraints.

SAES-L-150,

Para. 6.4

Final alignment,

specs

C5

Supports are installed. Additional temporary support may be

installed as required.

N/A

C7

Arc strikes, gouges, and other indications of careless workmanship

(such as surface porosity, uneven weld profiles, and undercut) shall be

removed by grinding and inspected by magnetic particle or liquid

penetrant method.

SAES-W-011,

Para. 11.6

SAES-W-011,

Para. 11.15.1

rework

provisions,

Controls,

retesting

C8Temporary welded attachments to the pipe were ground off and

inspected by magnetic particle or liquid penetrant method

SAES-W-011,

Para. 11.7

pack heavy

grease

C10Isolation valves are verified to have been body and seat tested prior to

installation through verification of field test certificates.

SAES-L-108,

Section 4.7

Valve

Installation

C9All threaded joints and faying surfaces shall be seal welded by a

continuous fillet weld (required weep holes shall be left unwelded).

C11All in line valves that are not used as test isolation valves are in open

position.

SAES-A-004,

Para. 7.3.2

SAES-A-004,

Para. 7.4.2

Valve Line-up

C12During water filling, Permanent vent and drain valves are in open

position and plugged, after water filling and air venting.

SAES-A-004,

Para 8.1.1

water removal

C14Disc of check valve is removed, unless check valve has by-pass.

Method for storage (plastic bag & tie) allows visual verification.

SAES-A-004,

Para. 7.4.3

WITNESS

POINT

C13 Drains are provided immediately above check valves (vertical lines).

Repairs

C15 Spare taps of orifice flanges are plugged and seal welded.SAES-L-110,

Para. 8.2

SAES-A-004,

Para. 7.2

C16All threaded joints up to the first block valve of hydrocarbon pipeline are

seal welded. Thread engagement has been verified & accepted.

SAES-L-110,

Para. 8.2

Reconnect

C18

The pressure testing manifold is separately pressure tested to at least

1.2 times the system test pressure but not less than the discharge

pressure of the pump used for the pressure testing.

SAES-A-004,

Para. 5.5.4Preservation

C17Process instruments and equipment that may be damaged by the

strength test pressure are disconnected.

M&TE

C19Buried pipeline are adequately bermed or covered to anchor the line

during pressure test.

SAES-L-450

Appendix C

SAES-A-004,

Para. 7.3.1

Inspection

C20Pressure gages and pressure recorders are calibrated within one (1)

month before the test. Check stickers at the time of th e test.

SAES-A-004,

Para. 7.1.5 (a)

P&ID Line-up

C22A bleed valve readily accessible is provided in case immediate

depressurization is required.

SAES-A-004,

Para. 5.5.2

C21Paddle or spectacle blinds shall be used to isolate test sections.

Safety of test "implements" has been checked (SAIC-A-2009)

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Reconnect

C23

EVALUATE CLEANING (PROCEDURES) & PROPOSED LAY-UPS:

For pipe up to 12-inch NPS - flushed clean of loose scale/debris or

scraped prior to commencement of pressure testing per procedureNote 1: If flushing was done with valves in line, cavity cleanliness is

highly suspect where no low point drains exist. Verify post-test removal

of scale/debris/water in low points (Check valve cavities).

Random veri f icat ion involves Inspect ion of valve cavi t ies.

This is a standard comm ent or addit ion to the punch l ist .

Note 2: Internal Cleaning procedure for pipe size larger than 14 inch

shall be submited for review and approval) See SATIP-L-108.

Flushing Cert is available in the test package for review

SAES-A-004,

Para. 7.1.2

Inspection

Excellence

Water removal

& Preservation

& LAY-UP

(Follow-up)

C24

All pressure containing components of pipeline, except instruments that

may be damaged by the test pressure, were physically verified to be

included in test using P&ID, ISOs (Pressure Test Diagram)

SAES-A-004,

Para. 5.6.1

Verify correct

specs all special

processes

C26

Use SAIC-A-2011 along with this

checklist (inspection efficiency)

whenever walkdown is done on

the same day as press. testing

As Referenced

C25PRE-TEST SPEC CHECK

SEE ATTACHMENT 4.

REMARKS:

REFERENCE DOCUMENTS:

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

2. SAES-L-105, Piping Material Specifications, (30 March, 2005)

3. SAES-L-108, Selection of Valves, (30 March, 2005)4. SAES-L-110, Limitations on Pipe Joints and Components, (30 March, 2005)

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

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

7. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003)

8. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005)

Contractor / Third-Party Saudi AramcoConstruction Representative* PMT Representative

Name, Initials and Date:

Work is Complete and Ready for Inspection:


T&I Witnessed QC Record Reviewed W ork Verified

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 = NO F = FAILED


SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 1-Dec-06 Piping-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE

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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

Pre-Test

Punch

Listing

(NOTE: Use form SATR-A-2007)

Construction Contractor QC

S. Aramco

Pre-Test

PunchListing

SAPMT 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)

Pressure

Testing Construction Contractor QC SAPMT PID Proponent

System

Lay-Up Construction Contractor QC SAPMT PID Proponent

(By Request)

Reinstate

System

Final Insp

(Contractor)Construction Contractor QC SAPMT

S. Aramco

Final Insp

for MCCSAPMT PID Proponent

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Attachment 3 -- Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)

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

SYSTEM TEST PRESS

& DURATION

TEST CONSIDERATIONS & NOTES

Process

Piping

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 of

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

*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.

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 psig,

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: 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 (check

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

Underground

Process Piping

As Calculated

See Notes

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

justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd.

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 B31.3Note: 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 high

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.

Vacuum Piping See Notes30 mins (min)

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

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 joints

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

Service tests and final gasket installation.

LP Steam

(60 psig max)

SERVICE TEST

30 mins (min)

Coordinate with system Service tests and construction completion.

Weld-Plus-Ends Soap Bubble LeakTest 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)

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

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

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

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

RETESTING

REQMTS

See Notes 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*.

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).

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 pressure

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

Open-EndedPiping

EXEMPT,VISUAL EXAM

Drains, vents & piping downstream of pressure relieving devices that discharge directly to theatmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc

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

Instrument

Impulse Lines

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: 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).

Internally FBE

Coated Lines

As Calculated*

30 mins (min)

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

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

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

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

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

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

Skid-Mounted

Piping (Vendor)

EXEMPT IF TESTED BY VENDOR

per 01-SAMSS-010

(exceptions noted)

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.

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

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

Exception See Note Low pressure pneumatic seat test at 5 psig shall be substituted for high pressurehydrostatic seat test for flare system valves. Identify & Segregate Early!!!

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

Procedure(Checklist Item D4)

See Note 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. See SAIC-L-2042

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

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

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

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

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

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.

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)

Boilers receiving 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&Is shall be per test pressure as specified on boiler's safety instruction sheet.

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

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

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

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

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

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

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

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

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

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

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

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).

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

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

Sanitary sewer lines outside of buildings shall 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 piping,

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

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

31-Dec-05



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Attachment 4 - SPEC CHECK INSTRUCTIONS1) Test Package Review Tool & Special Process Clearance Verification BEFORE Hydrotest.

a. Use Spec-Check along with SAIC-A-2003 (Checklist for Hydrotest Package Review) & this checklist.

b. Check test package Bill of materials against piping line class requirements (See sample Spec Check)

c. Check NDT requirements in SPEC-CHECK against NDT enclosed in given test packages. Check for correct NDT

extent specified and correct NDT methods. Check NDT reports and compare RT field markings to the test reports.d. Check RT reports closely for repairs (repair shots, penalties) & field verify the markings exist on the correct joint.

Note: If discrepancies exist, simply review the film and follow NDT checklists for RT (Clear direction exists here).

e. Shop/Field Weld NDT requirements vary and need to closely checked for omission of work. (10% shop, 100% fld)

f. Check PWHT reports against material spec requirements (service, thickness, etc). Verify visually PWHT was done

g. Check BHT reports against spec requirements (sweet & sour services). Verify roundness of Brinnell indentation.

h. PMI OK markings exist on those joints PMI examined. Verify markings to correct joint.

i. Check color codings of materials to assure correctly specified material was used in piping systems.

2) Check field installations (Pre-Hydro Walkdown, Surveillances) for following special processes:

a. Gasket Installation HOLD POINT FOR CONTRACTOR - Visual before installation, Color code Table

CRITICAL: COLOR CODES EXIST FOR ALL GASKETS (TABLE COVERS ALL GASKETS IN ALL LINE CLASSES)

b. Bolting Installation & Torque (Bolts, Nuts, Lubricants, Friction Factors, See Torque Tables)

c. Valve Installations (Check Valves installed against SAES-L-105 Spec Table Attached)d. Piping specs and piping schedules cab be included

e. Check Spectacle plates, blinds, spacers, Jack screws, etc for SPECIFIC SASD DRAWING conformance.

f. Check miscellaneous material elements (Class & pressure ratings for weld bosses, fittings) & Limitations (L-110)

g. Check WPS and any special instructions needed per welding (invaluable tool for Control)

3) Perform FOCUSED ASSESSMENTS with both CHECKLISTS & SPEC-CHECK

4) Perform Focused Assessments with Spec-Check alone on all specified Materials

5) Perform Focused Assessments with Spec-Check alone on Special Construction Processes.

6) Perform Post-Hydro Checks in the field (Reinstatement, FEIL, Pre-Commissioning, Commissioning)

a. During Reinstatement, Use Spec-Check along with SAIC-A-2010 (Checklist for Hydrotest Reinstatement) to

ensure correct installation (Bolting, valves, etc)

b. During FEIL walkdowns, use Spec-Check during accumulation of Field Exception Items List (FEIL)

c. During Final walkdowns, use Spec-Check one last time (Pre-Commissioning, Commissioning)

7) Add notes for: WPS Review/Compilation after Review of Line Class Tables, Valve Spec codes, flanges,

special walk down notes, supports, etc by using a numerical code and hand written notes on back!

SPEC-CHECK can be modified for any item. Ensure the best quality on your project! Check all specs

Test Package Review Notes1. Check status sheet for signoffs.

2. Check Index against contents

3. Pressure Test Data Sheet Check drawing numbers against actual enclosed Check excluded equipment & especially if there are any P&ID notes Check pressure test value proposed to assure limiting factor is correct (usually a flange)4. Do a Weld Tracker NDT report review (detailed) Compare completed Special Process reports (RT, MT, PT, PWHT, BHT, PMI, etc)

Compare against list of outstanding NDT (Backlog of Penalty & Repairs)5. Review P&IDs and isometrics against spec check for line class required materials (drawings often are in error)Note: Make note on cover in Punch list Accepted by PID Field verify against Spec/B.O.MThis is especially critical for Sour Service & Special Service lines.Note: Ensure orifice flange reports are included & any NDT specified6. Check hydrotest diagram Manifold arrangement sketches must show all elements, & manifold construction/insp must be per SAIC-A-2009Caution: Ensure test pressures do not exceed manifold element ratings (Valves are next size up for systems tested)Example 1: Class 300 # systems(1125 psi) would utilize a Class 600 Isolation valves in test manifolds at minimum.Example 2: A manifold with 800# gate valves will not be used in testing 600# systems (2250 psig)Reason: You are testing against the valve seat (closed position) & this is rated for 1.1 times test pressure, not 1.5.

See Next Page for Spec Awareness (Basis for Spec Check on Projects)

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SPEC AWARENESSPIDs ATTENTION TO SPECS & SPEC-Check(Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects:Initial Review of SPECS1. Carefully recheck Contractor Piping Specs (Line Class Summary & Tables) as early as possible during or just

after Design is complete (as soon as they are issued and available).2. This is done by checking Contractors specs against Line Class Material requirements listed in SAES-L-105. Givespecial attention to critical systems & systems above 300#.3. Average large projects can have as many as 50 different piping specs & details can be very hard to pick up in the

field. Pipelines have fewer specs and are easier to manage. THIS INCLUDES THE MAZE OF GASKETS!!!4. Time taken for early review only takes an experienced plant inspector 2 days of review. Findings (often humanerror) can be critical. Help prevent unplanned shutdowns on your projects & find substandard material specs beforethey are installed or before they enter service.5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon asthey are issued and available).6. This is done by checking Contractors Special Process Specs against code and SA requirements (SAES-W-011,Sect 17 for NDT & 13 for PWHT). SAES-W-012 is similar to SAES-W-011 in this respect7. Ensure that notes are included in these SPECS that require increased NDT based on field welding and other

code considerations.8. Clear violations such as our weekly highlight example (such as specs and drawings that use 3000# fittings on a900# system instead of required 6000# fitt ings) must be itemized & brought to SAPMT attention early.See attached Sample Weekly Highlight.9. After all SPECS submitted by Contractor are accepted ... CREATE your custom SPEC-CHECK (sampleattached with instructions).Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task forself-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* andsubstandard installation identification*.*FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWAREOF MANY CRITICAL REQUIREMENTS! SPEC CHECK PUTS THESE DOWN ON PAPER (BY SYSTEM)

Test Package Review & Pre-Hydro Walkdow

1. Follow-up (after initial specification review/approval) can also include checking ISO drawings and bill of materialsagainst approved specs before Pre-Hydro Walkdown2. USE YOUR CUSTOM SPEC-CHECK on every new plant project as the perfect walk down and test packagereview tool. Important Note: Never assume drawings or test packages are correct. Never assume NDE % & PWHT,PMI, etc performed/not performed by contractor is correct.Inspectors must be taught a systematic review method for test packs with focus on Specs.A thorough test package review system is a page by page review that takes only 15 minutes per package & checksevery page and every weld & all materials for completeness/correctness. Omission of Special Process work byContractor is widespread & frequent, most often unintentional and simply due to a lack of AWARENESS.

Surveillance & Focused Assessment1. Use SPEC-CHECK on routine surveillance.

2. Create a custom SPEC-CHECK for focused assessments on Valves.Incorrect valve installation is very common with valves placed in the wrong service (swapped, mislocated, mismark)3. Create a custom SPEC-CHECK for focused assessments on small diameter piping (UT purposes). Past projectshave seen as many as 20% of all piping segments installed of the wrong schedule of piping (J-80, RT Refinery). Ivisit projects and find numerous substandard installations very often (human error, again). On your project,order/request/perform/get Contractor to do random checks of small diameter piping segments (2 & below). I do itmyself with a 2-man crew with me, piping schedules in hand on all my projects & run at about a 2% reject rate.4. Create a custom SPEC-CHECK for focused assessments on PWHT & BHT. Past projects have seen poorpractice with failure to follow 12-step BHT procedure per NACE RP-0472 App A.5. Turn your project surveillance into an effective and efficient Inspection asset that is valuable to Projects.

SHARE SPEC CHECK WITH YOUR CONTRACTOR FOR QUALITY




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Plug, cap seal

welding, PT

N/A

Final alignment,

specs

rework

provisions,

Controls,

retesting

RE-INSP DATEITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS N/A

Tolerances,

specs

WITNESS

POINT

Final & Perm

Gasket Install

Water removal

Lay-up

Final Coating

& Insulation

Protection

Controls

Plan/Strategy

Valve Line-up

pack heavy

grease

C4Vents and drain valves, both temporary and permanent, conforms with

the piping class or rating. ( Refer SAES-L-108)

SAES-L-105,

Para. 5.9

C5

Supports are installed. Additional temporary support may be

installed as required.

SAES-A-004,

Para 8.1.1

Buried pipeline are adequately bermed or covered to anchor the line

during pressure test.

SAES-L-450

Appendix C

SAES-L-110,

Para. 8.2Spare taps of orifice flanges are plugged and seal welded.

All threaded joints up to the first block valve of hydrocarbon pipeline are

seal welded. Thread engagement has been verified & accepted.

FAIL

C22

QR NUMBER

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006

SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED

1-Dec-06 Piping-

Repairs

SAES-L-108,

Section 4.7

Valve

Installation

SAES-W-011,

Para. 11.7

Arc strikes, gouges, and other indications of careless workmanship

(such as surface porosity, uneven weld profiles, and undercut) shall be

removed by grinding and inspected by magnetic particle or liquid

penetrant method.

SAES-W-011,

Para. 11.6

All in line valves that are not used as test isolation valves are in open

position.

SAES-L-150,

Para. 6.2

SAES-L-150,

Para. 6.3

C

C3

C2All permanent flange jointswere inspected, gasket mat'l verified &

properly torqued. (Review Flange joint report, SAIC-L-2014)

SAES-L-450,

Para. 9.4

Isolation valves are verified to have been body and seat tested prior to

installation through verification of field test certificates.

C8

Expansion joints and spring hangers or spring supports are provided with

temporary restraints.

SAES-L-150,

Para. 6.4

Temporary welded attachments to the pipe were ground off and

inspected by magnetic particle or liquid penetrant method

C7

Drains shall be provided at all low points of the piping system.

Note: Exceptions are submarine & buried* pipelines (*pump-outs)

C1

All joints (flange, threaded, welded or mechanical seals) are left exposed

for visual leak detection during the strength test.

A) External coating & priming of joints is allowed only if approved by Insp

Dept Mgr & proponent Organization Representative.

B) The pipe itself can be externally primed & coated to a final coat.

SAES-L-150,

Para. 7.3

System

clearance

(Controls)

C12

C14

During water filling, Permanent vent and drain valves are in open

position and plugged, after water filling and air venting.

C6

C11

C10

SAES-A-004,

Para. 7.3.2

C13 Drains are provided immediately above check valves (vertical lines).SAES-A-004,

Para. 7.4.2

SAES-A-004,

Para. 7.2

SAES-L-110,

Para. 8.2

SAES-A-004,

Para. 5.5.4

A bleed valve readily accessible is provided in case immediate

depressurization is required.

SAES-A-004,

Para. 5.5.2

C21Paddle or spectacle blinds shall be used to isolate test sections.

Safety of test "implements" has been checked (SAIC-A-2009)

SAES-A-004,

Para. 7.3.1

SAIC-A-2010 Checklist (Reinstatement Procedure & Checklist item required (when bold.

P&ID Line-up

water removal

Reconnect

M&TE

C16

The pressure testing manifold is separately pressure tested to at least

1.2 times the system test pressure but not less than the discharge

pressure of the pump used for the pressure testing.

C17Process instruments and equipment that may be damaged by the

strength test pressure are disconnected.

Preservation

Inspection

C9All threaded joints and faying surfaces shall be seal welded by a

continuous fillet weld (required weep holes shall be left unwelded).

SAES-W-011,

Para. 11.15.1

C15

Disc of check valve is removed, unless check valve has by-pass.

Method for storage (plastic bag & tie) allows visual verification.

SAES-A-004,

Para. 7.4.3

SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS (See E-Library, Folder 25)

C20Pressure gages and pressure recorders are calibrated within one (1)

month before the test. Check stickers at the time of th e test.

SAES-A-004,

Para. 7.1.5 (a)

C18

C19

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RE-INSP DATEITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS N/AFAIL

QR NUMBER

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED

1-Dec-06 Piping-

C26

Use SAIC-A-2011 along with this

checklist (inspection efficiency)

whenever walkdown is done on

the same day as press. testing

As Referenced

QC Inspector PID Representative

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

2. SAES-L-105, Piping Material Specifications, (30 March, 2005)

3. SAES-L-108, Selection of Valves, (30 March, 2005)4. SAES-L-110, Limitations on Pipe Joints and Components, (30 March, 2005)

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

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

7. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003)

8. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005)


Performed Inspection Work / Rework May Proceed


Construction Representative*


Work is Complete and Ready for Inspection: T&I Witnessed


PMT Representative

REFERENCE DOCUMENTS:

REMARKS:

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

T&I Witnessed QC Record Reviewed

Name, Sign and Date:

QC Record Reviewed

Work Verified

Contractor / Third-Party

Quality Record Approved:Name, Organization,

Initials and Date:


Saudi Aramco

Work Verified

QC Supervisor Proponent and Others

Verify correct

specs all special

processes

C24

All pressure containing components of pipeline, except instruments that

may be damaged by the test pressure, were physically verified to be

included in test using P&ID, ISOs (Pressure Test Diagram)

SAES-A-004,

Para. 5.6.1Reconnect

C25PRE-TEST SPEC CHECK

SEE ATTACHMENT 4.

Inspection

Excellence

Water removal

& Preservation

& LAY-UP

(Follow-up)

C23

EVALUATE CLEANING (PROCEDURES) & PROPOSED LAY-UPS:

For pipe up to 12-inch NPS - flushed clean of loose scale/debris or

scraped prior to commencement of pressure testing per procedureNote 1: If flushing was done with valves in line, cavity cleanliness is

highly suspect where no low point drains exist. Verify post-test removal

of scale/debris/water in low points (Check valve cavities).

Random veri f icat ion involves Inspect ion of valve cavi t ies.

This is a standard comm ent or addit ion to the punch l ist .

Note 2: Internal Cleaning procedure for pipe size larger than 14 inch

shall be submited for review and approval) See SATIP-L-108.

Flushing Cert is available in the test package for review

SAES-A-004,

Para. 7.1.2

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

Review Procedure - Post Test Reinstatement & Checklist Piping-SAIC-A-2006 1-Dec-06



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

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Review Procedure - Post Test Reinstatement & Checklist Piping-SAIC-A-2006 1-Dec-06



S. Aramco

Pre-Test

Punch

ListingSAPMT PID Proponent

(By Request)

Clear 'A'

Items Construction Contractor QC

Clear

S. Aramco

'A' ItemsConstruction Contractor QC SAPMT

SAPMT

Construction Contractor QC SAPMT

Construction

S. Aramco

Final Insp

for MCCSAPMT PID

Reinstate

System

Final Insp

(Contractor)Construction Contractor QC

Flushing &

Cleanliness

Proponent

Proponent

System

Lay-Up Construction Contractor QC SAPMT PID Proponent

(By Request)

Pressure

Testing

Attachment 2 -- TEST PACKAGE FLOW CHART

PIDContractor QC SAPMT

Test Pack

Preparation Engineering Contractor QC

Pre-Test

Punch

ListingConstruction Contractor QC

PID Proponent

(By Request)

(NOTE: Use form SATR-A-2007)

PID

Test Package (or Test System) No

Page 13 of 18

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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 exceed

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-EndedPiping

EXEMPT,VISUAL EXAM

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

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 joints

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

Service tests and final gasket installation.

LP Steam

(60 psig max)

SERVICE TEST

30 mins (min)

Coordinate with system Service tests and construction completion.

RETESTING

REQMTS

Process

Piping

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 (check

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

Underground

Process Piping

As Calculated

See Notes

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

justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd.

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

Weld-Plus-Ends

See Notes

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

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 of

pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process requestsper 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 psig,

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.

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 high

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 - Post Test Reinstatement & Checklist SAIC-A-2006 1-Dec-06

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

Piping-



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)

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

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

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

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

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*.

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Procedure(Checklist Item D4)

See Note 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. 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 be

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 unique

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

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

segregation control to 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.

Boilers receiving 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&Is shall be per test pressure as specified on boiler's safety instruction sheet.

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.

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)

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

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.

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 to

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

Sanitary sewer lines outside of buildings shall 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 piping,

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).

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

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!!!

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

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

Potable water piping outside of buildings shall 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 SAES-

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 tanks;

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

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

Page 15 of 18

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f. Check miscellaneous material elements (Class & pressure ratings for weld bosses, fittings) & Limitations (L-110)

Test Package Review Notes1. Check status sheet for signoffs.

3) Perform FOCUSED ASSESSMENTS with both CHECKLISTS & SPEC-CHECK

h. PMI OK markings exist on those joints PMI examined. Verify markings to correct joint.

7) Add notes for: WPS Review/Compilation after Review of Line Class Tables, Valve Spec codes, flanges,

i. Check color codings of materials to assure correctly specified material was used in piping systems.

CRITICAL: COLOR CODES EXIST FOR ALL GASKETS (TABLE COVERS ALL GASKETS IN ALL LINE CLASSES)

Manifold arrangement sketches must show all elements, & manifold construction/insp must be per SAIC-A-2009

e. Check Spectacle plates, blinds, spacers, Jack screws, etc for SPECIFIC SASD DRAWING conformance.

g. Check WPS and any special instructions needed per welding (invaluable tool for Control)

4) Perform Focused Assessments with Spec-Check alone on all specified Materials

6) Perform Post-Hydro Checks in the field (Reinstatement, FEIL, Pre-Commissioning, Commissioning)

ensure correct installation (Bolting, valves, etc)

c. During Final walkdowns, use Spec-Check one last time (Pre-Commissioning, Commissioning)

d. Piping specs and piping schedules cab be included

6. Check hydrotest diagramNote: Ensure orifice flange reports are included & any NDT specifiedThis is especially critical for Sour Service & Special Service lines.



Attachment 4 - SPEC CHECK INSTRUCTIONS

2. Check Index against contents


1) Test Package Review Tool & Special Process Clearance Verification BEFORE Hydrotest.

Piping-

Note: If discrepancies exist, simply review the film and follow NDT checklists for RT (Clear direction exists here).

Caution: Ensure test pressures do not exceed manifold element ratings (Valves are next size up for systems tested)Example 1: Class 300 # systems(1125 psi) would utilize a Class 600 Isolation valves in test manifolds at minimum.

g. Check BHT reports against spec requirements (sweet & sour services). Verify roundness of Brinnell indentation.

a. Use Spec-Check along with SAIC-A-2003 (Checklist for Hydrotest Package Review) & this checklist.

Check drawing numbers against actual enclosed

extent specified and correct NDT methods. Check NDT reports and compare RT field markings to the test reports.

b. Bolting Installation & Torque (Bolts, Nuts, Lubricants, Friction Factors, See Torque Tables)

c. Valve Installations (Check Valves installed against SAES-L-105 Spec Table Attached)

SPEC-CHECK can be modified for any item. Ensure the best quality on your project! Check all specs

Compare completed Special Process reports (RT, MT, PT, PWHT, BHT, PMI, etc)

Example 2: A manifold with 800# gate valves will not be used in testing 600# systems (2250 psig)

c. Check NDT requirements in SPEC-CHECK against NDT enclosed in given test packages. Check for correct NDT

b. Check test package Bill of materials against piping line class requirements (See sample Spec Check)

e. Shop/Field Weld NDT requirements vary and need to closely checked for omission of work. (10% shop, 100% fld)

f. Check PWHT reports against material spec requirements (service, thickness, etc). Verify visually PWHT was done

2) Check field installations (Pre-Hydro Walkdown, Surveillances) for following special processes:

a. Gasket Installation HOLD POINT FOR CONTRACTOR - Visual before installation, Color code Table

d. Check RT reports closely for repairs (repair shots, penalties) & field verify the markings exist on the correct joint.

3. Pressure Test Data Sheet

Compare against list of outstanding NDT (Backlog of Penalty & Repairs)5. Review P&IDs and isometrics against spec check for line class required materials (drawings often are in error)Note: Make note on cover in Punch list Accepted by PID Field verify against Spec/B.O.M

5) Perform Focused Assessments with Spec-Check alone on Special Construction Processes.

a. During Reinstatement, Use Spec-Check along with SAIC-A-2010 (Checklist for Hydrotest Reinstatement) to

b. During FEIL walkdowns, use Spec-Check during accumulation of Field Exception Items List (FEIL)

special walk down notes, supports, etc by using a numerical code and hand written notes on back!

Check excluded equipment & especially if there are any P&ID notes Check pressure test value proposed to assure limiting factor is correct (usually a flange)4. Do a Weld Tracker NDT report review (detailed)

Reason: You are testing against the valve seat (closed position) & this is rated for 1.1 times test pressure, not 1.5.

See Next Page for Spec Awareness (Basis for Spec Check on Projects)

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Piping-

PIDs ATTENTION TO SPECS & SPEC-Check(Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects:

SPEC AWARENESS

Initial Review of SPECS1. Carefully recheck Contractor Piping Specs (Line Class Summary & Tables) as early as possible during or just

after Design is complete (as soon as they are issued and available).2. This is done by checking Contractors specs against Line Class Material requirements listed in SAES-L-105. Givespecial attention to critical systems & systems above 300#.3. Average large projects can have as many as 50 different piping specs & details can be very hard to pick up in the

field. Pipelines have fewer specs and are easier to manage. THIS INCLUDES THE MAZE OF GASKETS!!!

900# system instead of required 6000# fitt ings) must be itemized & brought to SAPMT attention early.See attached Sample Weekly Highlight.9. After all SPECS submitted by Contractor are accepted ... CREATE your custom SPEC-CHECK (sample

4. Time taken for early review only takes an experienced plant inspector 2 days of review. Findings (often humanerror) can be critical. Help prevent unplanned shutdowns on your projects & find substandard material specs beforethey are installed or before they enter service.5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon asthey are issued and available).6. This is done by checking Contractors Special Process Specs against code and SA requirements (SAES-W-011,

against approved specs before Pre-Hydro Walkdown2. USE YOUR CUSTOM SPEC-CHECK on every new plant project as the perfect walk down and test packagereview tool. Important Note: Never assume drawings or test packages are correct. Never assume NDE % & PWHT,PMI, etc performed/not performed by contractor is correct.Inspectors must be taught a systematic review method for test packs with focus on Specs.

Sect 17 for NDT & 13 for PWHT). SAES-W-012 is similar to SAES-W-011 in this respect7. Ensure that notes are included in these SPECS that require increased NDT based on field welding and other

code considerations.

substandard installation identification*.

8. Clear violations such as our weekly highlight example (such as specs and drawings that use 3000# fittings on a

have seen as many as 20% of all piping segments installed of the wrong schedule of piping (J-80, RT Refinery). I

*FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWAREOF MANY CRITICAL REQUIREMENTS! SPEC CHECK PUTS THESE DOWN ON PAPER (BY SYSTEM)

Test Package Review & Pre-Hydro Walkdow

attached with instructions).Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task forself-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* and

A thorough test package review system is a page by page review that takes only 15 minutes per package & checksevery page and every weld & all materials for completeness/correctness. Omission of Special Process work by

1. Follow-up (after initial specification review/approval) can also include checking ISO drawings and bill of materials

Contractor is widespread & frequent, most often unintentional and simply due to a lack of AWARENESS.

Surveillance & Focused Assessment1. Use SPEC-CHECK on routine surveillance.

2. Create a custom SPEC-CHECK for focused assessments on Valves.Incorrect valve installation is very common with valves placed in the wrong service (swapped, mislocated, mismark)3. Create a custom SPEC-CHECK for focused assessments on small diameter piping (UT purposes). Past projects

4. Create a custom SPEC-CHECK for focused assessments on PWHT & BHT. Past projects have seen poorpractice with failure to follow 12-step BHT procedure per NACE RP-0472 App A.5. Turn your project surveillance into an effective and efficient Inspection asset that is valuable to Projects.

SHARE SPEC CHECK WITH YOUR CONTRACTOR FOR QUALITY

visit projects and find numerous substandard installations very often (human error, again). On your project,order/request/perform/get Contractor to do random checks of small diameter piping segments (2 & below). I do itmyself with a 2-man crew with me, piping schedules in hand on all my projects & run at about a 2% reject rate.

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4 Valves (400 SS Trim) tested in-line removed, cleaned, & lubricated for Amb lay-up ditto

12 All Temporary Test Components (spools, test blinds, gaskets etc) are removed ditto

15 All Start-up items installed (strainers, filters, other items restricted from test) ditto14 Check Valves and internals reinstalled (Internal Cleanliness & gasket check) ditto

NOTES: a. Above Items are samples for form use only.

b. Re-instatement Procedure shall detail specific items to be used in this Re-

Instatement checklist (per SAEP-1160, Sect. 8). The above 17 items are a sample

of such a procedure checklist.

c) Indicate " No Post Test items. " as applicable

d). QA col is reviewed/initialed/dated prior to package certification to verify

completeness

I

T

E

M

Reinstatement (Post-Test) Checklist Items &

Description (Option per Note 5 Above)

Reference &

Applicable

SATIP

A

or

B

Origi-

nator

ETC

(Note 6)

Verified

complete

by QC

Concur

PID Insp

SAES-A-007,

Para 6.2B DEF-1/4/07

RLC

1/4/07

ABC/QC 1/1/2007

ABC/QCStart-up date =

5/1/2007

ABC/QC 1/4/2007

SAES-L-110,

Section 5A

SAEP-351,

Proj DwgsB

DEF-1/4/07RLC

1/4/07

DEF-1/1/07RLC

1/1/07

ABC/QC 1/4/2007

SAES-L-108,

Section 5A

SAES-L-108,

Section 6B

DEF-1/1/07RLC

1/1/07

SAES-L-109,

Section 8A

ABC/QC 1/1/2007

1/1/2007

6) ETC = Expected Time of Completion or Expected Start-up Date if ETC date is unknown (affects lay-up considerations)

DEF-1/1/07RLC

1/1/07

SAES-L-109,

Section 8A

DEF-1/1/07RLC

1/1/07

Note: "B" items not complete during re-instatement (by approved procedure) shall be transferred to "zFEIL Form 6133" (Attachment 2)

1 Seal weld threaded nipples from headers to root valves at (5) locations (hydrocarbonservice) per SAES-L-109, Section 8.

Origi-

nator

ETC

(Note 6)

2 Guides are in direct contact with piping horizontal run at 3 locations (6mm gap req'd).Relocate guides per drawing. These are welded to the pressure boundary.

ABC/QC 1/1/2007

ABC/QC

6 Install permanent gaskets at flange sets 1, 4, 5, 6 on ISO dwgs per approved torquetables and install spectacle blinds oriented as per approved P&ID.

4) "B" items are completed during re-instatement per an approved Procedure before final inspection by Company (per procedure).

Verified

complete by

QC

Concur

PID Insp

I

T

E

M

Pre-Pressure Test Checklist Items & Description ReferenceA or

B

5) See SATR-A-2011 for Re-instatement Checklist Form.

QR NUMBER

NOTES: a. Above Items are samples for form use.

b. Indicate " No Punch items. " as applicable

c. QA col is reviewed/initialed/dated prior to package certification to verify

completeness

4 Check valve is oriented in the wrong direction (flow arrow). Reverse check valve toassure correct flow direction. Reposition valve & restore internals immediately after

test, COMPANY to witness.5 Piping clearance to structural bracing is 15 mm in violation of SAES-L-310, Sect 12.

(50 mm spacing req'd). Engineering!

7 Completely remove all water and debris from low point/valve cavity for the (3) in-lineValves (8" - 300 #) with SS 400 trim, do so immediately after test. Clean with dry

compressed air and relubricate sealing surfaces with approved lubricant in preparation

for "ambient" lay-up specified in test package.

8

WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

SAUDI ARAMCO TEST REPORTSATR NUMBER

3 Check valve upstream clearance is not five (5) pipe diameters (40" req'd, 20" actual),in violation of SAES-L-108.

TEST SYSTEM No./Test Pack No.

DATE APPROVED

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION

1-Oct-06 MECH-Pre-Pressure Test Checklist (Form) SATR-A-2007PROJECT TITLE

PLANT NO.

WORK PERMIT REQNATURE OF TESTDRAWING NUMBER (P&ID/ISO) / REV. No. PRESSURE TEST DIAGRAM

Notes:

SAUDI ARAMCO TIP (SATIP) NUMBER

1) This Form shall be used in conjunction with applicable Pre-Pressure Test Checklist. Refer to applicable SATIPs & See Attachment 1

2) "A" items are items required to be completed before pressure test can proceed.

3) "B" items are post-test items to be cleared immediately after pressure test (within 24 hours) with Inspection witness per procedure.

1 Flushing & hydrotest complete and documented as accepted. ReinstatementProcedure

2 All test vents & drains plugged and seal welded ditto

3 Lines drained and lay-up per customer approved specification ditto

5 Jacking screws, process blinds (spectacles, spades, etc) correctly installed ditto

6 Spring Hangers & components (bellows, etc) adjusted per mfg instructions. ditto

7 Weepholes plugged with heavy grease (reinforcement pad air test complete) ditto

8 Chain wheel operators installed ditto

9 All instruments, control valves & check valves reinstalled in correct flow position ditto

10 Restriction orifice/flow elements installed ditto

11 Relief Valves are Pop tested/calibrated, tagged and SAP approved/installed ditto

13 Correct bolts/gaskets are installed and torqued per SAEP-351 requirements ditto

16 Chemical Cleaning completed and documented

17 Final Line Check complete & meets all special process specs. See Spec Check.

ATTACHMENT 5 (Guide for Post-Test Reinstatement Checklist by Contractor)


SATIP Activity No. SUPPORTING SAIC Number SAIC QR No.

saic-a-2006 rev 2

Documents