Inspection Procedure

00-SAIP-06

31 August, 2004

Pressure Test Requirements

Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards

Table of Contents
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Scope.............................................................
References.....................................................
Pressure Test Requirements.........................
Special Test...................................................
Reporting Methods.........................................

Previous Issue: 31 December, 2000 Next Planned Update: 1 September, 2009

Revised paragraphs are indicated in the right margin
Primary contact: Nasser M. Balhareth on 874-6604

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Document Responsibility: Inspection Department

Issue Date: 31 August, 2004
Next Planned Update: 1 September, 2009

00-SAIP-06
Pressure Test Requirements

Scope
1.1

This SAIP is to highlight certain pressure test requirements, identify special

tests, explain reporting methods and to provide instructions for witnessing
pressure tests on new or existing equipment and piping.

1.2

This SAIP does not include pressure test requirements for the following:
Construction of On-Land and Near Shore Pipelines SAES-L-450

Installation of Freon Refrigeration System

SAES-K-xxx Series

Plumbing Installations

UPC

Hot Tap Connections

SAES-L-052

Thermoplastic Pipe

SAES-S-xxx Series

Reinforced Thermosetting Resin Pipe

SAES-S-xxx Series

Bottled Gas Cylinders

BGM (Bottled Gas Manual)

References
The following standards were used in the preparation of this procedure and should be
carefully reviewed by the inspector prior to witnessing pressure tests:
Saudi Aramco References
Saudi Aramco Engineering Standards
SAES-A-004

Pressure Testing

SAES-A-005

Applicable Safety Instruction Sheets

SAES-A-007

Hydrostatic Test Fluids and Required Lay-ups

SAES-B-017

Fire Water Systems

SAES-L-150

Pressure Testing of Plant Piping and Pipelines

General Instruction
GI-0002.102

Pressure Testing Safely

Saudi Aramco Forms

SA 2093-ENG

Equipment Inspection Record-General

SA 2642-ENG

Pressure Test Report

SA 2642-1-ENG

Pressure Test Information Sheet

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Document Responsibility: Inspection Department

Issue Date: 31 August, 2004
Next Planned Update: 1 September, 2009
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00-SAIP-06
Pressure Test Requirements

Pressure Test Requirements

3.1

Both Relief and Bleed Valves are required for all piping and equipment under
test. (SAES-A-004 para. 5.5)

3.2

The inspector shall witness and accept the flushing procedures prior to
commencement of pressure test. (SAES-A-004, para. 7.1.2)

3.3

Filling and Draining of the system under test shall be performed carefully to
prevent entrapped air or formation of a vacuum. (SAES-A-004, para. 8 and 9)

3.4

Firewater Systems shall be tested for 4 hours in accordance with SAES-B-017.

3.5

Pressure Sewers shall be tested under the same conditions as for pressure piping.

3.6

Buried lines should be tested before backfilling. In cases where a trench has
been backfilled prior to a pressure test, a 24-hours pressure/temperature
recorded test is required per SAES-L-150.

3.7

Welded connections that are impractical to pressure test may be 100% inspected
by NDE in lieu of a pressure test (SAES-A-004, para. 5.6.2). The Appendix of
SAES-A-004 shall be used for reporting and approving NDE in lieu of pressure
test. This sheet should be submitted to the applicable approval authority at least
24 hours prior to the actual test.

3.8

Safety requirements described in SAES-A-004 shall be reviewed and closely

followed when pressure testing.

3.9

Hydrostatic test diagrams and procedures shall be provided by the operations

engineering groups within an operating plant or the contractor for new projects,
to the inspector prior to conducting the test. Refer to SAES-A-004, para. 5.6.1
for details of these documents.

3.10

The pressure test manifold shall be separately tested at 1.2 times the system test
pressure prior to the actual system pressure test. (SAES-A-004, para. 6.5.4)

Special Test
Pneumatic and Inert Gas test procedures shall be submitted and approved prior to
testing by the Manager, Inspection Department except where allowed by SAES-A-004
and SAES-L-150. Loss Prevention shall also approve the pneumatic test procedures
when air is used and the equipment has previously been in flammable service. Refer to
SAES-A-004, para. 5.2.

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Document Responsibility: Inspection Department

Issue Date: 31 August, 2004
Next Planned Update: 1 September, 2009
5

00-SAIP-06
Pressure Test Requirements

Reporting Methods
5.1

The Pressure Test Information sheet (Form 2642-1-ENG) shall be completed by

the assigned inspector for each pressure test.

5.2

The Appendix of SAES-A-004 shall be completed and approved for all NDE in
lieu of pressure test as described above in para. 4.7.

5.3

Permanent recording of pressure test results shall be made on the Pressure Test
Report (Form 2642-ENG).

31 August, 2004

5.3.1

A copy of the Pressure Test Report shall be sent to the Construction

agency on new projects.

5.3.2

Records should also be entered in the Equipment Inspection Record,

General (Form 2093-ENG). Both forms will go into the plant record
books for either turn-over to Operations Inspection or for the plant
record books after a test is conducted by the Operations Inspection
personnel.

Revision Summary
Revised the "Next Planned Update". Insure the contents of the document, delete items
number (2) "Purpose", updated referenced documents and done editorial changes.

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