SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -March 2010)

Rev 4
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

SAIC-A-2010

PROJECT TITLE

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

CONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

NOTE: Use Pre-test Punch List Form, SATR-A-2007, for listing of specific deficiencies, indicating location and/or references
A

Test Pack Verification & Review* (*Thorough & detailed review of specs for each new system's first package)

A1

Test Package has been verified to be approved and to contain the

detailed elements of SAEP-1160, Sect 8 as detailed in SAIC-A-2003.
Use Attachments 1 & 2 of this checklist (quick reference).

SAES-A-004,
Para. 5.6.1
Schedule Q AttIV para 3.7

A2

Pressure Testing Procedure is approved. Test application meets SA

reqmts as checked against Pressure Test Matrix - Attach. 3.

SAES-A-004,
Para. 5.6.1

A3

Construction & Special Process Control (per SAEP-1160 Database) has

been documented as complete* (ready for Punch Listing).
Welding, NDT, PWHT, BHT, PMI, Other Testing, is documented in pkg
Procedure is followed regarding Test Pkg flow sequence.

SIS Sheet Data Verification (Safety Considerations & Limiting Factors in Pressure Test Calculations)

B1

SIS shall be prepared for all individual units of plant equipment which in
view of size, pressure rating and application are within the scope of
Saudi Aramco Engineering Standards and general industry codes

Page 1 of 12

SAEP-1160,
Section 6
Weld Database

SAES-A-005
Para 4.2

RE-INSP DATE

A Safety Instruction Sheet is prepared for each piece of process

equipment. Each SIS shall include, in addition to tabulated information,
all significant and unusual hazards, recommendations, unusual
inspections and tests relating to the piece of equipment. References to
be used in preparing the SIS include design drawings, vendor's
drawings, vendor's certificates, and
inspection reports.
A) Pressure rating of flanges (per ASME B16.5 or other)
B) Pressure rating of any valves used in isolation (ASME B16.34)
Note: (Valve pressure ratings for seat closure = tested at 110% when
valves are used for isolation)
C) Other system components (Internal Coating pressure rating) may
result in test pressure reduction APCS 102 = 3,000, others 5,000psi
B2

SAES-A-005
Para 5.1

Test Pressure=2t(0.9)(SMYS)/D where:

t= nominal pipe wall thickness minus the specified mill tolerance*
*mill tolerance =12.5% (seamless pipe) or .01" for welded plate SMYS=
Specified minimum yield strength (psi). Use ASME B31.3 Appendix A
Tables for specific material grade used (SIS sheet).
Example: SMYS for API 5L Gr X-60 = 60 KSI or 60,000 psi
D = Outside piping diameter (OD)* ... Per ASME B36.10 Tables
*Note: For nominal piping sizes 14" (& above), actual O.D. = 14"
For nominal pipe sizes 12" & below ... See ASME B36.10 Tables

On SIS sheets, proposed hydrostatic strength test pressures for

EXISTING PLANT PIPING SYSTEMS (TIE-INS) is the test pressure
shall be minimum required by the Code ASME B31.3. Actual min wall
thickness of piping shall be verified (PROCEDURE) and used in such
calculations. Thickness readings are current (30 days) & flange rating is
considered when calculating test pressure (ASME B31.3)

B3

Test Pressure=2t(0.9)(SMYS)/D where:

t= ACTUAL PIPING WALL THICKNESS (MINIMUM MEASURED)
SMYS= Specified minimum yield strength (psi). Use ASME B31.3
Appendix A Tables for specific material grade used (SIS sheet).
Example: SMYS for API 5L Gr X-60 = 60 KSI or 60,000 psi
D = Outside piping diameter (OD)* ... Per ASME B36.10 Tables
*Note: For nominal piping sizes 14" (& above), actual O.D. = 14"

Page 2 of 12

SAES-A-004
para 4.2

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

31-Mar-10
DATE APPROVED
QR NUMBER

SAIC-A-2010

PROJECT TITLE

ITEM
No.

Rev 4
SAIC NUMBER

31-Aug-11

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

PASS

Punchlisting Field Walkdown (Pressure Piping Systems):

SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS

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

C2

All permanent flange joints were inspected, gasket mat'l verified &
properly torqued. (Review Flange joint report, SAIC-L-2014)

SAES-L-450,
Para. 9.4

C3

Drains 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

C4

Vents 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-L-150,
Para. 6.3

C6

Expansion joints and spring hangers or spring supports shall be provided

with temporary restraints where needed to prevent excessive travel or
deformation under the test loads.

SAES-L-150,
Para. 6.4

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

C8

Temporary welded attachments to the pipe were ground off and

inspected by magnetic particle or liquid penetrant method

SAES-W-011,
Para. 11.7

C9

All 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

C10

a) If requested by the proponent, all new valves designated for isolation

service (as specified by the Proponent) shall be subjected to a high
pressure hydrostatic seat test prior to installation in the line
b) Buttweld and socketweld end valves in nominal pipe size (NPS) 2
inches and smaller are exempt from the above field testing requirements

SAES-L-108,
Section 4.7

C11

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

SAES-A-004,
Para. 9.1.3

C12

During filling, permanent vent valves are in open position. Plugging is

only AFTER WATER FILL & EFFICIENT AIR VENTING.

SAES-A-004,
Para9.1.1

C13

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

SAES-A-004,
Para. 8.4.2

C14

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. 8.4.3

C15

Spare taps of orifice flanges are plugged and seal welded.

SAES-L-110,
Para. 9

C16

All threaded joints up to the first block valve of hydrocarbon pipeline are
seal welded. Thread engagement has been verified & accepted.

SAES-L-110,
Para. 9.2

C17

Process instruments and equipment that may be damaged by the

strength test pressure are disconnected.

SAES-A-004,
Para. 8.2

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. 5.5.4

Page 3 of 12

Piping-

CONTRACTOR / SUBCONTRACTOR

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

Rev 4
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

SAIC-A-2010

PROJECT TITLE

WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

C19

Buried pipeline are adequately bermed or covered to anchor the line

during pressure test.

SAES-L-450
Appendix C

C20

Pressure gages and pressure recorders are calibrated within one (1)
month before the test. Check stickers at the time of the test.

SAES-A-004,
Para. 8.1.5.2

C21

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

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

SAES-A-004,
Para. 8.3

C22

A bleed valve readily accessible is provided in case immediate

depressurization is required.

SAES-A-004,
Para. 5.5.2

C23

Components in new piping systems which interfere with filling, venting,

draining or flushing shall not be installed until after line flushing and
pressure testing are completed. These include orifice plates, flow
nozzles, sight glasses, venturies, positive displacement and turbine
meters and other in-line equipment.

SAES-A-004,
Para. 8.1.4

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

REMARKS:
REFERENCE DOCUMENTS:
1.
2.
3.
4.
5.
6.
7.
8.

SAES-A-004, General Requirements for Pressure Testing, (14-Dec-2009)

SAES-L-105, Piping Material Specifications, (8-Aug-2009)
SAES-L-108, Selection of Valves, (21 December, 2005)
SAES-L-110, Limitations on Pipe Joints and Components, (18 May 08)
SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (1-Nov-2008)
SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 June, 2009)
SAES-W-011, Welding Requirements for On-Plot Piping, (4-Oct-2009)
SAES-A-005, Safety Instruction Sheet (21-March-2010)

Contractor / Third-Party

PMT Representative

Construction Representative*
Name, Initials and Date:

Work is Complete and Ready for Inspection:

QC Inspector
Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

PID Representative
Performed Inspection

Work / Rework May Proceed

QC Supervisor
Name, Sign and Date:

Name, Initials and Date:

Saudi Aramco

Name, Initials and Date:

Proponent and Others

Quality Record Approved:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 4 of 12

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

Rev 4
SAIC NUMBER

SAIC-A-2010

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

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

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

Page 5 of 12

Piping-

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

Rev 4
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

SAIC-A-2010

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

Attachment 2 -- TEST PACKAGE FLOW CHART

Test Package (or Test System) No
Test Pack
Preparation

Engineering

Contractor QC

Pre-Test
Punch
Listing

Construction

Contractor QC

Clear 'A'
Items

Construction

Contractor QC

SAPMT

PID

Proponent
(By Request)

Clear
S. Aramco
'A' Items

Construction

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)

Construction

Contractor QC

SAPMT

S. Aramco
Pre-Test
Punch
Listing

Reinstate
System
Final Insp
(Contractor)

S. Aramco
Final Insp
for MCC

(NOTE: Use form SATR-A-2007)

Page 6 of 12

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test
Punch Listing of On-Plot Piping
S. Aramco
Final Insp
for MCC

SAPMT

Rev 4
SAIC NUMBER

SAIC-A-2010
PID

Proponent

Page 7 of 12

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

Rev 4
SAIC NUMBER

SAIC-A-2010

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

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

ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)
TEST PRESS
TEST CONSIDERATIONS & NOTES
& DURATION
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 requests
per Sect 6 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 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.

Lube & Seal Oil

Systems

See Notes
30 mins (min)

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 B31.3

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

Vacuum Piping

See Notes
30 mins (min)

Air & Inert Gas

(150 psig max)

SERVICE TEST &

Soap Bubble Test
30 mins (min)
SERVICE 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.

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.

LP Steam
(60 psig max)
Weld-Plus-Ends

Existing Plant
Piping
Incl. Tie-Ins

As Calculated*
30 mins (min)

RETESTING
REQMTS

See Notes

Coordinate with system Service tests and construction completion.

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*.

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-Ended
Piping

EXEMPT,
VISUAL EXAM

Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
atmosphere (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.

Page 8 of 12

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping
Instrument
Impulse Lines

As Calculated*
30 mins (min)

Rev 4
SAIC NUMBER

SAIC-A-2010

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

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.

Sampling Lines

See Note

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

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 EXEMPT IF TESTED BY VENDOR 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,
per 01-SAMSS-010
Piping (Vendor)
(exceptions noted)

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)
See Note
Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Test Location
All new valves designated for isolation service (as specified by the Proponent) shall be
See
Note
Field Testing of
subjected to high pressure hydrostatic seat test prior to installation in line.
New Valves
Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure
See Note
Exception
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!

Exemption
Procedure
(Checklist Item D4)

See Note

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

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 (Piping
System, 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-situ prior 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 SAESK-001 and the Uniform Mechanical Code (UMC), Section 1520.

Page 9 of 12

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

Rev 4
SAIC NUMBER

SAIC-A-2010

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

6.8 Potable Water Systems - Potable water piping inside buildings shall be tested per the reqmts of Uniform 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.

Page 10 of 12

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

Rev 4
SAIC NUMBER

31-Mar-10
DATE APPROVED
QR NUMBER

SAIC-A-2010

31-Aug-11

Piping-

Attachment 4 - SPEC CHECK INSTRUCTIONS

1) 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 Notes

1. 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.M
This is especially critical for Sour Service & Special Service lines.
Note: Ensure orifice flange reports are included & any NDT specified
6. Check hydrotest diagram
Manifold arrangement sketches must show all elements, & manifold construction/insp must be per SAIC-A-2009
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.
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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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut off Date- March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST

Pre-Test Punch Listing of On-Plot Piping

Rev 4
SAIC NUMBER

SAIC-A-2010

31-Mar-10
DATE APPROVED
QR NUMBER

31-Aug-11

Piping-

SPEC AWARENESS
PIDs ATTENTION TO SPECS & SPEC-Check
(Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects:
Initial Review of SPECS
1. 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. Give
special 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 human
error) can be critical. Help prevent unplanned shutdowns on your projects & find substandard material specs before
they are installed or before they enter service.
5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon as
they 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 respect
7. 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 a
900# system instead of required 6000# fittings) 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
attached with instructions).
Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task for
self-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* and
substandard installation identification*.
*FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWARE
OF 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 materials
against approved specs before Pre-Hydro Walkdown
2. USE YOUR CUSTOM SPEC-CHECK on every new plant project as the perfect walk down and test package
review 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 & checks
every page and every weld & all materials for completeness/correctness. Omission of Special Process work by
Contractor is widespread & frequent, most often unintentional and simply due to a lack of AWARENESS.

Surveillance & Focused Assessment

1. 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
have seen as many as 20% of all piping segments installed of the wrong schedule of piping (J-80, RT Refinery). I
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 it
myself 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 poor
practice 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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