Saudi Aramco

Inspection Department

Training & Contractor Workforce Saudization Group

PRESSURE TESTING
PEW-406.03

The training materials contained in this module are the property of the Saudi Arabian Oil Company (Saudi Aramco) and
are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses. Any
material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given or
disclosed to third parties or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramcos
Professional Engineering Development Unit courses without the prior written permission of the Chief Engineer of Saudi
Aramco

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DATE

REVISION DESCRIPTION

12/06/04

COMPLETE REVISION

REVISION

PAGE(S) AFFECTED
ALL

S.U. BASHA, S. CAVE, M. AKKAD

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MODULE COMPONENT
OBJECTIVES

TABLE OF CONTENTS

PAGE
1

Terminal Objective

Enabling Objectives

INTRODUCTION
Purpose
TYPES OF PRESSURE TESTS
Types of Test Media

2
2
3
3

Hydrostatic Tests

Pneumatic Tests

Types of Pressure Tests

Strength Test

Tightness Test

Leak Test

Service Test

Revalidation Test

EVALUATE PRESSURE TEST PROCEDURE

SAES-A-004

SAES-L150

GI 2.102

Verify Test Flow Diagram

10

Verify Test Pressure

11

Plant Piping

12

Piping Components

13

Valves

17

Cross-country Piping

21

Heat Exchangers

23

Boilers and Pressure Vessels

24

Variables that Affect Pressure

28

VERIFY SYSTEM READINESS

Visual Inspection

32
32

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Drains and Vents

32

Test Manifold

33

Protection of System Components

34

Pressure Gauges, Recorders, and Relief Valves

35

WITNESS PRESSURE TESTING

Witness System Pressurization

43
43

Paragraph 5.13 Remove Air before Pressurizing (Liquid Test)

43

Paragraph 5.14 Control Pressure Rise

43

Paragraph 5.16 Restrict Approach to the System

43

Witness Strength and Tightness Tests

44

Strength Test

44

Tightness Test

44

Tests of In-service Equipment

45

Witness System Depressurization

45

Paragraph 5.19 Depressurize Safely

45

Paragraph 5.20 Dispose of Test Media Safely

45

Paragraph 5.21 Follow Additional Safety Precautions

45

DOCUMENT THE PRESSURE TEST

Report Strength and Tightness Tests

47
47

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EXERCISE 1.

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TABLE OF CONTENTS

VERIFY TEST PROCEDURE

48

Exercise 1A. Verify Test Procedure: Hydrotest Diagram and P&ID

48

Exercise 1B. Verify Test Procedure: Calculate Test Pressures

49

Exercise 1C. Verify Correct Gauge

50

EXERCISE 2.

VERIFY SYSTEM READINESS

51

EXERCISE 3.

DOCUMENT PRESSURE TEST

52

WORK AID 1.

PROCEDURES FOR EVALUATING PRESSURE TEST

PROCEDURE

53

PROCEDURES FOR VERIFYING SYSTEM READINESS

54

WORK AID 2.

Work Aid 2A. Procedures for Visually Inspecting Test Pressure, Relief Valves,
Pressure Gauges, Witness Pressure Testing And Record The
Results.
GLOSSARY

56
57

ADDENDUM A:

PRESSURE REPORT FORM

59

ADDENDUM B:

TABLES

61

ADDENDUM C.

HYDROSTATIC TEST PROCEDURE

83

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OBJECTIVES

OBJECTIVES
Terminal Objective
Upon completion of this module, the Participant will be able to inspect pressure test
preparations and witness a pressure test in accordance with applicable standards.

Enabling Objectives
In order to accomplish the Terminal Objective, the Participant will be able to:

Identify different types of pressure tests

Evaluate a pressure test procedure for compliance with applicable Saudi Aramco
and industry standards.

Verify system readiness for pressure testing in accordance with SAES-A-004,

SAES-L-150 and SAES-B-017.

Witness pressure testing.

Document pressure tests.

Note:

This training material has been developed using the latest available versions of applicable
Saudi Aramco and industry standards. However, these documents are regularly updated.
Therefore, it is the responsibility of the Inspector to ensure that he is conducting his
inspections according to the latest, updated version of these documents.

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INTRODUCTION
Pressure testing is required by most piping codes to verify that a new, modified, or
repaired piping system is capable of safely withstanding its rated pressure and is leak
tight. Pressure testing may also be used to establish a pressure rating for a component
or special system for which it is not possible to establish a safe rating by calculation.

Purpose
The purpose of pressure testing is to ensure the safety and reliability of plant and field
equipment. Pressure testing is one of the methods the inspector uses to determine that
equipment is safe for operation. The piping and much of the equipment that Saudi
Aramco uses is designed to contain fluids under pressure. Pressure testing checks the
ability of piping and equipment to withstand operating design pressures.
Stresses in components during a pressure test are normally permitted to go as high as
90% of the material yield point. This approach ensures that the components will be
exposed to a much higher stress than they will experience in service, but under wellcontrolled conditions. If no defects are found under these conditions, then the piping
integrity has been demonstrated.
Once welds have been properly designed for their purpose, and are of the necessary
quality, one more step is necessary to ensure that the piping system is sound. It must be
pressure tested. Saudi Aramco requires pressure testing of piping systems and
equipment.
All defects that are found from weld inspection must be repaired before the pressure
test. If the defects are not repaired, pipe failure may result. The objective of the pressure
test is to bring the piping system to a high enough internal pressure under controlled
conditions, such that its mechanical integrity has been demonstrated. Once the pressure
test has been conducted, the item is considered acceptable for operation.

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TYPES OF PRESSURE TESTS

Types of Test Media
Different types of tests and test media are used in combination to evaluate safe and
reliable operation of plant and field equipment.
There are two types of test media for use with pressure tests, namely liquid or gas.
Tests that use liquid as a test medium are called hydrostatic tests. Tests that use a gas
as a test medium are called pneumatic tests.

Hydrostatic Tests
Hydrostatic testing is the preferred leak-testing method and perhaps the most often used
because of its inherent safety. Hydrotesting uses water as the test medium. If a leak at
a weld develops during a hydrotest, the internal pressure immediately drops because
water is an incompressible fluid, and therefore causes no major damage.
Nevertheless, there can still be a substantial risk associated with a hydrostatic leak test.
The danger in a hydrostatic test is mainly due to air trapped in the piping. Even if all air is
vented from the piping before pressurizing, workers are well advised to conduct any
high-pressure test with safety in mind.

Pneumatic Tests
Tests that use a gas as a test medium are called pneumatic tests. Pneumatic means
pressure exerted by a gas. The gas can be air or another gas approved by Saudi
Aramco for use in given testing situations.
Saudi Aramco uses the pneumatic pressure test for some testing situations where
hydrostatic tests are not appropriate. For example, flare lines 24-inch NPS and larger
with a design pressure of 517 kPa (ga) (75 psig) or lower may be pneumatically strength
tested per SAES-L-150.
There are additional safety considerations for pneumatic pressure tests because the gas
test mediums compress under pressure. Compressed gas has a much greater potential
for energy release than the liquid test mediums used in the hydrostatic pressure tests.
Consequently, there is greater risk of injury to personnel if the vessel or piping fails
during the test. GI 2.102 specifies the necessary safety requirements for pneumatic
testing.
Inspection for a leak is usually done with a soapy-water mixture that is applied to the
joints. In case of a leak, bubbles form as air or gas escapes.

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Most often compressed air or bottled Nitrogen gas are used for pneumatic test.
However, Nitrogen should not be used in a closed area if the possibility exists that the
escaping nitrogen could displace the air in the confined space. Persons have been
known to become unconscious under such circumstances before realizing they were
short of oxygen.
Because of the greater danger of injury with a gaseous test medium, the pressure that
may be used for visual examination for leaks is lower for some piping codes than is the
case for a hydrostatic test.
Warning: Do not approach any piping or equipment during pneumatic
pressurization or while it is at strength test pressure. If the piping or
equipment fails during the strength test, the resulting explosive
pressure release could kill bystanders and/or seriously damage
surrounding equipment.
Warning: Never hammer test any piping or equipment that is undergoing a
pneumatic pressure test. The piping or equipment could be damaged,
resulting in an explosive release of pressure. Bystanders could be
injured or killed, and surrounding equipment damaged.
Warning:

Warning:

Air is not approved for use as a test medium in any system that was
in hydrocarbon service unless the system has been thoroughly
cleaned. Thorough cleaning is necessary to avoid an explosive
hydrocarbon-air mixture.
In no case will oxygen or any toxic gas be used as a test medium.
These gases present extreme hazards to personnel and equipment.

Pressure rise must be gradual and kept under control to allow time for material to strain.
This also provides personnel with time to check for leaks.

Approval from the Proper Authority

Certain types of systems, such as low-pressure lines and dry-pipe fire protection
systems, require pneumatic pressure tests. Others can be pneumatically tested as an

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alternative to hydrostatic testing. SAES-A-004 and other pertinent standards provide

specific information.
Pneumatic testing is not permitted without written approval of the Manager, Inspection
Department, unless specifically allowed by this standard or the referenced Saudi Aramco
SAESs or SAMSSs. This test, when conducted, shall be in accordance with GI0002.102 for additional safety requirements.
Pneumatic testing with air of piping systems or equipment which have been in flammable
service shall be concurred by the Manager, Loss Prevention Department. The test
procedures shall include cleaning/purging procedures to avoid explosive flammable air
mixtures.

Types of Pressure Tests

The following describes various types of pressure tests and their purposes. Each test
can be either a hydrostatic test or pneumatic test (if approved):

Strength test

Tightness test

Leak test

System test

Service test

Revalidation test

Strength Test
A Strength Test is a pressure test at an internal pressure as decided by applicable code
that is high enough to verify the integrity of the piping and/or equipment for service at the
Maximum Allowable Working Pressure (MAWP). API 570 defines MAWP as the
maximum internal pressure permitted in the piping system for continued operation at the
most severe condition of coincident internal or external pressure and temperature
expected during service.
During this test, the equipment shall not be subject to impact. The test pressure shall be
maintained for a duration of not less than 30 minutes for plant piping, 2-hours for
pipelines, 4- hours for fire water lines etc.,

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A strength test is applied in the following cases:

Before piping system is initially placed in service.

After repairs or alterations have been made that affect the strength of pressure
containing parts, except as noted in SAES-A-004.

At intervals as specified by Equipment Inspection Schedules.

Tightness Test
A Tightness Test is a pressure test, which is conducted at 95% of the strength test
pressure. Tightness test is done immediately after the strength test and its purpose is to
ensure that there is no leakage in the system. For pipelines, a 24-hour recorded
tightness test shall be applied at this pressure when pipeline is buried

Leak Test
A Leak Test is a pressure test to demonstrate that there are no leaks in flanges or
threaded joints at the test pressure. Leak tests are normally conducted by Operations
during startup or commissioning of the facilities, using approved plant procedures, and
are outside the scope of SAES-A-004.

Service Test
A Service Test is a strength test performed to prove the integrity of pipelines or plant
piping using the service fluid at the maximum attainable operating pressure.
Plant utility piping in air and inert gas services with a design pressure (equal or less than
150 PSI) and low pressure steam piping designed for 60 PSI, are usually subjected to
the service test.

Revalidation Test
A Revalidation Test is a pressure test that is meant to prove the integrity of existing
cross- country pipelines or plant piping. This test is conducted at the option of, and at the
intervals set by, the responsible operating organization. For revalidation purposes of
existing plant piping, the test pressure shall be minimum required by ASME B 31.3

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EVALUATE PRESSURE TEST PROCEDURE

Test procedures, including hydrostatic test diagrams, shall be prepared by the
responsible engineering group and made available to Inspection prior to conducting the
test. The test procedures and diagrams shall include the limits of piping (including test
manifold) and equipment included in each hydrostatic test. Furthermore, test pressures,
test temperature, test fluid, line flushing requirements, and safety precautions shall also
be included. Prior to the hydrotest, the Inspector shall verify the following:

Verify approved test procedure

Verify test flow diagrams

Verify test pressures

Verify additional Requirements

Verify Approved Test Procedure

All pressure tests must be controlled by an approved test procedure. Pressure test
procedures are governed by these Saudi Aramco documents:

SAES-A-004

SAES-L-150

GI 2.102

Other Saudi Aramco standards and procedures may also apply, depending on the
specific equipment being tested. These documents also refer to many national and
industry standards. The specific equipment that will be tested determines exactly which
standards apply. The details of the pressure test procedure must comply with the
applicable standards.
The Inspector is not required to know the details of every standard. However, he must
be able to locate and use the necessary standards in order to ensure that the test
procedure complies. If there is a conflict between two or more specified standards, follow
the guidelines of SAES-A-004.

SAES-A-004
SAES-A-004 provides specific guidance about pressure testing:

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Scope

Definitions

General Requirements

Test Preparation

Test Procedure

Test Pressure, Temperature and Duration

Appendix: Request for 100% Radiography in Lieu of Hydrotest

INFORMATION

SAES-L150
SAES-L-150 defines mandatory requirements governing pressure testing of newly
constructed plant piping and pipelines that are designed and constructed in accordance
with ASME B31.1, ASME B31.3, ASME B31.4, or ASME B31.8 codes as applicable.
Moreover, SAES-L-150 covers pressure testing existing plant piping and pipelines for
revalidation purposes or after repairs. SAES-L-150 covers the following items:

Scope

Definitions

General Requirements

Design Requirements

Pressure Testing of Plant Piping

Pressure Testing of Pipelines

Pressure Testing for Minor Repairs

Pressure Testing of Miscellaneous Piping Components

Test Procedures

GI 2.102
GI 2.102 specifies safety information necessary for pressure testing. As part of the
safety precautions for pressure testing, GI 2.102 (6.0) specifies that all pressure test
procedures must be approved by the Chief Inspection Engineer of the Consulting
Services Department.

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GI 2.102 also provides a checklist that the Inspector uses to verify that all necessary
information is covered by the pressure test procedure. The checklist is divided into 19
sections; the first 12 fall under the heading Before Start of Test
1.

Assign Responsibility

2.

Issue Written, Approved Procedures

3.

Use Proper Test Medium

4.

Select and Treat Hydrostatic Test Water

5.

Use Appropriate Test Equipment

6.

Obtain Work Permits

7.

Isolate Equipment Not Adequate for Test Pressure

8.

Prevent Overloads from Weight of Liquid

9.

Handle Chemicals Safely

10.

Avoid Failure by Brittle Fracture

11.

Control Access to the Test Site

12.

Advise Government Affairs of Non-Saudi Aramco Exposures

The remainder falls under the heading During and After Test
13.

Remove Air before Pressurizing (Liquid Test)

14.

Control Pressure Rise

15.

Depressurize Before Stopping Leaks or Repairing

16.

Restrict Approach to the System

17.

Depressurize Safely

18.

Dispose of Test Mediums Safely

19.

Follow Additional Safety Precautions

The Inspector follows the items on this checklist to review the procedure, its attachments
and other documents cited in the procedure.

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Verify Test Flow Diagram

The Inspector determines which equipment and piping, including piping components, will
be tested. This group of process components is usually referred to as the system under
test, and can be found by examining the test flow diagram, also known as the hydrostatic
test diagram. The hydrostatic test diagram is used for both hydrostatic and pneumatic
pressure tests. The hydrostatic test diagram shows the limits of the test, including the
location of isolation blinds (See Figure 1).
The hydrostatic test diagram may also show the locations of low-point drains and highpoint vents, as well as the arrangement of the test manifold. If these items do not appear
on the hydrostatic test diagram, they will be provided on separate isometric drawings. The
Inspector must also verify these separate drawings.

Figure 1. Test flow diagram

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Verify Test Pressure

The limiting factor for any pressure test is the pressure rating of the weakest component
in the system under test. The pressure test procedure or the hydrostatic test diagram will
specify which component limits the test pressure. The Inspector first verifies that the
specified limiting component has the lowest pressure rating within the system under test.
He then determines that the correct test pressure has been specified.
The Inspector will usually be required to verify the pressure for the following systems:

Plant piping

Piping components

Valves

Cross-country pipelines

Heat exchangers

Boilers and pressure vessels

Additionally, the Inspector should be familiar with the following factors that affect pressure
tests:

Elevation

Temperature

After calculating the test pressure for the limiting component, the Inspector compares the
result of his calculations to the pressure listed in the hydrostatic testing procedure. If the
two numbers are different, the Inspector notifies his supervisor.
Both internal and external corrosion and erosion reduce the thickness of the metal in
piping and vessel parts. Therefore, the Inspector compares recent thickness
measurements with the thickness minimums (tm) for the vessels and piping to determine
if all the components are within their respective design safety factors. He may decide to
take thickness measurements of components that are near their tms or that show signs of
an increasing rate of thinning. The equipment history contains this thickness information,
and the SISs contain the tm for vessels and critical piping.
The Inspector contacts his supervisor and the engineering group concerned if he finds
any component that cannot withstand the specified test pressure, or if his calculations
indicate that the specified test pressure is incorrect. If the pressure ratings for all the
components meet or exceed the pressure specified for the test, then the system can be
tested safely.

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Plant Piping
Unless limited by flanges, valves or other components in the line, the hydrostatic
strength test pressure for every section of new constructed line shall produce a hoop
stress in the pipe of 90% of the specified minimum yield strength (SMYS) at the test
temperature per SAES-L-150. The test pressure shall be calculated based on the pipe
nominal wall thickness less the mill tolerance (manufacturer's minus tolerance). The test
pressure shall not be less than the minimum test pressure per ASME B31.3 paragraph
345.4.2.
Calculation for the minimum hydrostatic test pressure (per hoop stress) for plant piping is
as follows:

Pt = 2(.9YT)
D
Where,
Pt = minimum test pressure
Y = specified minimum yield strength of the pipe material
T = nominal pipe thickness x .875
D = outside diameter of pipe, in inches
The value for Y can be determined from Table A-1 in ASME B31.3 (See also Addendum)
The values for D and nominal pipe thickness can be determined from a commercial pipe
schedule derived from ASME B36.10 and B36.19. "Dimensions and Minimum Nozzle
Thickness of Seamless and Welded Steel Pipe".
SAES-L-150 also states that the test pressure shall not be less than the minimum test
pressure per ASME B31.3, regardless of the above calculation. The calculation for the
minimum test pressure for ASME B31.3 is as follows:
Pd = 2SEt
D

Pt = 1.5(Pd)

Where;
Pt = minimum test pressure
Pd = maximum allowable operating pressure
S = maximum allowable stress for a given temperature

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E = longitudinal joint efficiency

t = nominal pipe thickness
D = outside diameter of pipe
The value for S can be determined from Table A-1 B31.3 (See Addendum)
The value for E can be determined from Table 302.3.4 or Table A-1B in B31.3 (See
Addendum)
Example
The example shows both formulas with values substituted for the variables. The values
are based on 6" NPS Std, A-106, Grade B seamless piping, operating at 2000 F or less.

Test per hoop stress:

Piping

Piping Components
The test pressures for flanges and valves are calculated according to ASME B16.5.
More specifically, Sec. 8.3 of B16.5 lists the requirements for hydrostatically testing
flanged fittings as follows:

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The hydrostatic shell test for flanged fittings shall be no less than 1.5 times the
1000oF rating rounded off to the next higher 25 psi increment.

The test shall be made with water, which may contain a corrosion inhibitor, with
kerosene, or with another suitable fluid, provided its viscosity is no greater than
that of water, at a test temperature not above 125 F.

The test duration shall be a minimum of 1 minute for fittings NPS 2 and smaller, 2
minutes for fittings NPS 2-1/2 - NPS 8, and 3 minutes for fittings NPS 10 and
larger.

No visible leakage is permitted through the pressure boundary wall.

To determine the maximum test pressure for a forged flange, the Inspector refers to
ASME B16.5, Table 1A, List of Material Specifications (See Figure 2), and Table 2,
Pressure Temperature Ratings (See Figure 3). Table 1A is used to determine the
material of the flange. Table 2 is used to determine the operating pressure at a given
temperature

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Figure 2. List of Material Specifications (Table 1A - ASME B16.5)

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Figure 3. Pressure-temperature Rating (Table 2 ASME 16.5)

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Example
Calculate test pressure of a flange with Spec. A-105, class 150, and an operating
temperature in the -200C to 380C range.
Answer
The Forgings column of Table 1A shows A-105 at the top of the column. Reading to the
left shows that this is carbon steel, in Material Group 1.1. Table 2.1.1 shows that the
operating pressure for this flange is 19.6 BAR. Operating pressure is first multiplied by
1.5. To get BAR converted to PSI multiply by 14.5
19.6 BAR x 14.5 = 285 PSI
285 PSI x 1.5 = 427.5 PSI
This answer is then rounded up to the next higher 25 psi increment; thus, the test
pressure is 450 psi.
Example
Calculate the test pressure for a flange with Class 1500, made of the same material,
operating in the same temperature range as the previous Example.
Answer
According to Table 2.1.1, the operating pressure is 255.3 BAR. The operating pressure
is first multiplied by 1.5:
255.3 BAR x 14.5 = 3,698 PSI

3698 PSI x 1.5 = 5,547 PSI

This answer is then rounded up to the next higher 25 psi increment; thus, the test
pressure is 5550 psi.

Valves
Repaired and new valves require pressure testing. There are two main types of test,
hydrostatic strength tests of the shell and hydrostatic seat tests of the valve seats. When
performing a hydrostatic test of the shell, the valve ends shall be closed, the valve
partially open and any packing gland tight enough to maintain the test pressure. Figure 4
shows hydrotesting of valves.

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Figure 4. Hydrotesting of valves

Table 1-A, Table 1-B, Table 4 and Table 5 (Figures 5 and 6) show pressure test
requirements, holding durations, acceptable leakage rates as per API-598.

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Figure 5. Pressure test requirements (API-598)

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Figure 6. Test Duration and Leakage Rates (API-598)

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Cross-country Piping
This is the formula for calculating test pressures for cross-country piping (See Figure 7):

The yield strength can be found in API Specification 5L, Specification for Line Pipe,
Table 3A (See Figure 8). The nominal thickness can be determined from a commercial
pipe schedule derived from ASME B36.10 and B36.19. A partial table is seen on page
75, "Dimensions and Minimum Nozzle Thickness of Seamless and Welded Steel Pipe

Figure 7. Cross-country Pipeline

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Figure 8. Tensile Requirements for PSL 1 (API 5L)

Example
Calculate test pressure for an 8" nominal diameter, seamless, Schedule 40, API 5L
Grade B, carbon steel pipe, operating at 200 F or less.
Answer

Example
Calculate the test pressure for a 42" nominal diameter, electric fusion welded, Schedule
40, API 5L Grade B, carbon steel pipe, operating at 2000 F or less.

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Heat Exchangers
The following are the five main hydrostatic pressure tests that pertain to heat
exchangers (See Figure 9):
Preliminary Test:

To determine which exchanger in a bank of exchangers is leaking.

Initial Tube Test:

To determine if either the floating head gasket or the tubes are

leaking.

Ring Test:

To determine which tubes in the bundle are leaking.

Final Tube Test:

To verify that a repaired bundle is leak free after installation in the

shell.

Shell Test:

Final test, verifies the integrity of the fixed tube sheet to shell, and
shell to shell cover flange joints.

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Figure 9. Heat Exchangers

Boilers and Pressure Vessels

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Normally, Boilers and Pressure Vessels are pressure-tested when new or after major
repairs. The two tests required are for strength and tightness. The procedure is covered
by GI 2.102 and SAES -A- 004.
For field fabricated vessels or vessels requiring field repairs or alterations, the
hydrostatic testing shall be conducted in accordance with ASME SEC VIII D1, UG-99 or
D2, T-4 as applicable. The hydrostatic test pressure at the top of the vessel shall be 1.5
times (for D1 vessels) and 1.25 times (for D2 vessels) the MAWP (maximum allowable
working pressure).
The vessel must be adequately supported during hydrotest if it is tested out of position.
The primary stresses occurring during testing shall not exceed 90% of yield stress.
For existing vessels undergoing repairs or alterations, the testing shall be same as
above. However, the strength of the existing foundations shall be confirmed to be
adequate for the additional weight of the hydrostatic fluids.
Hydrostatic test pressure for existing vessels under T&I shall be in accordance with the
routine test pressure as specified on the Safety Instruction Sheets.
Pneumatic test, when approved, shall be conducted per UG-100 of ASME SEC VIII D1,
or T-4 of ASME SEC VIII D2, whichever is applicable. The procedure for pneumatic test
per ASME VIII requires that pressure in the vessel be gradually increased to not more
than one-half of the test pressure. Thereafter, the test pressure shall be increased in
steps of approximately one-tenth of the test pressure until the required test pressure has
been reached. Then the pressure shall be reduced to a value equal to four fifths of the
test pressure and held for a sufficient time to permit inspection of the vessel.
The visual inspection of the vessel at four-fifths of the required test pressure may be
waived provided:
(1)

a suitable gas leak test is applied;

(2)

substitution of the gas leak test is by agreement reached between Manufacturer

and Inspector;

(3)

all welded seams which will be hidden by assembly be given a visual

examination for workmanship prior to assembly;

(4)

the vessel will not contain a "lethal" substance.

There shall be holds of at least 10 minutes at each step to permit inspection for leaks
and weaknesses. Pressure cannot be taken to the next step until all leaks have been
stopped and all weaknesses have been repaired.
Strength tests are observed from a safe distance, as specified by G.I. 2.102, and
monitored with pressure gauges and/or pressure recorders.

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A leak method used for tank floors or vessels is the vacuum box test. For reinforcing
pads, the bubble test with positive pressure can be used. Both tests use a solution of
soap water to detect leaks.
Vacuum Box Test
Vacuum box bubble emission leak testing performed in accordance with ASTM E-515,
provides for the detection of through-thickness discontinuities in welds (See Figure 10).
It is used during construction to test welds of incomplete systems that cannot be
pressurized. It is also used to test pressure boundary welds that are inaccessible for leak
testing when the entire system is pressurized. It may also be used to create a pressure
differential for increasing the sensitivity of penetrant leak testing techniques.
Typical discontinuities detectable by this method are cracks, pores and lack of fusion. A
bubble forming solution is applied to the surface to be examined. A vacuum box with a
viewing window large enough to view the complete area and to allow sufficient light to
enter the box for proper examination is placed over the test surface and evacuated.
A calibrated pressure gauge is placed in the vacuum-box system to verify the required
pressure differential under test. The surface area visible through the vacuum box
window is then viewed for evidence of through-thickness discontinuities by the formation
of bubbles on the surface. Through-thickness discontinuities are indicated by the
formation of a continuous chain of bubbles in the film solution. Through-thickness
discontinuities are usually considered unacceptable, and such welds should be repaired
and retested.

Figure 10. Vacuum box test

Reinforcement Pads

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INFORMATION

The diagram illustrates testing of a reinforcement pad by the use of Bubble test. First, a
strength test is applied at 25 psig (173 kPa) through a tapped vent hole and then the
pressure is dropped to 3-5 psig (21-35 kPa) for a tightness test. A bubble solution is
applied to the test area during the tightness test. If any leakage is indicated, release the
air pressure, repair, retest by the same procedure (See Figures 11 and 12)

Figure 11. Bubble test on reinforcement pads of equipment

Figure 12. Bubble test on a reinforcement pad of piping

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INFORMATION

Variables that Affect Pressure

Elevation
Where the pipeline traverses hilly terrain, the elevation gradient must be carefully
considered in selecting pipeline segments to be tested to ensure the specified allowable
percentages of the specified minimum yield strength (SMYS) are within the tolerance
quoted.
If water is used as a test medium, the test gradient must be based on water head in feet.
Water pressure may be converted to head by dividing the pressure by 0.433. If seawater
is being used as a test medium, a factor of 0.455 should be used. This assumes a
specific gravity of 1.02 for seawater. In any case, the factor of 0.433 should be modified
according to the specific gravity of the test medium.
Example

Assume that a line needs to be tested and the elevation of the test site is 100 feet. The
elevation at the end of the line is 150 feet. Fresh water will be used as a test medium
and it is desired to test the pipe to a minimum of 90% and a maximum of 95% of the
SMYS of the pipe. The pipe is 30" OD x 0.390" wt API 5L X60.
Answer

The difference in elevation is 50 feet, which corresponds to a pressure of 21.7 psig (50
feet x 0.433 = 21.7 psig). A test pressure equal to 90% of the SMYS is 1,404 psig, since
the test site is lower than the high end of the line, the 21.7 psig is added to the 1,404
psig to obtain a test site pressure of 1,426 psig. The pressure at the end of the line will
be 1,404 psig, which equates to 90% of the SMYS. The pressure at the low point will be
1,426 psig, which equates to 91.4% of SMYS.
Temperature
Pressure changes for a change in test water temperature and this pressure change can
be estimated by means of the following calculations and charts.
Example

Pipe data

18 OD x 0.375

Water Temperature (start)

70oC

At time t

66oC

Test Pressure

1,800 psi

Calculate

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INFORMATION

D/t = 18 / 0.375 = 48
Where

D = pipe OD, in.

T = Pipe wall thickness, in.

Calculate

Average temperature = (70 + 66) / 2 = 68oC

Use the chart, enter at 68oC and at the intersection with D/t line representing 48, read 21
psig / oC
Calculate

70oC - 66oC = 4oC

4 x 21 = 84 psi
Therefore, a pressure drop 84 psi, giving a final pressure of:
1,800 84 = 1,716 psig

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INFORMATION

Basis of chart development

dP = [B 2a] / [(D x (1 v2) / Et + C]

where,
dP

psig change per oC

Coefficient of expansion of water

Pipe OD, in.

Modulus of elasticity of steel

Poissons ratio

Compressibility factor for water

Coefficient of expansion of steel

Pipe wall thickness, in.

Temperature oC

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INFORMATION

VERIFY SYSTEM READINESS

Visual Inspection
After reviewing the test procedure and the hydrostatic test diagram, the inspector
performs a visual inspection of the test preparations in the field or at the plant under test
to ensure that the requirements of SAES-A-004 have been met.
The Inspector verifies that the equipment on the hydrostatic test diagram matches the
equipment being tested. The pressure ratings on the hydrostatic test diagram should
match the pressure ratings on the equipment. The test limits should be clearly indicated
on the test diagram along with the locations of temporary blinds. The Inspector verifies
that blinds are as indicated on the diagram. The Inspector verifies the following items:

Drains and vents

Test manifold

Protection of system components

Pressure gauges, recorders and relief valves

Drains and Vents

SAES-A-004 specifies that vents and drains must be properly located throughout the
system under test (See Figure 13). Vents must be located at high points in the system
so that all air can be removed as the system fills with test medium (water). The inspector
checks that all parts of the system have a vent and that no dead legs exist in the system.
Dead legs are places where air can be trapped by rising water as the system fills. The
Inspector must verify that the necessary vents are in place, as specified by the
hydrostatic test diagram or the separate isometric drawing.
Paragraph 7.4 of SAES-A-004 specifies exceptions to the vent requirements.
Drains must be located at low points throughout the system under test (See Figure 13).
These drains provide locations to remove the water from the system after the test is
completed. The inspector checks that no dead legs exist where water can be trapped as
the system drains. This step is especially important for piping in high temperature
processes, because the water can vaporize: suddenly into steam during startup. The
sudden vaporization of water in a piping system can cause damage to the plant.

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INFORMATION

The Inspector must verify that the necessary drains are in place, as specified by the
hydrostatic test diagram or the separate isometric drawing. Paragraph 9.3 of SAES-A004 specifies exceptions to the drain requirements.

HIGH POINT VENT

LOW-POINT
DRAINS

Figure 13. Placement of vents and drains

Test Manifold
GI 2.102 and SAES-A-004 specify that the test manifold used to connect the test pump
and to provide pressure release and blow down piping must meet or exceed the
pressure requirements specified for the test. Test manifolds must be pre-tested at a
pressure 20% higher than the test pressure specified for the system under test.

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INFORMATION

There must be a valve to isolate the test pump from the system under test. SAES-A-004
specifies that the test pump must be isolated from the system under test during the hold
periods and during visual inspection.
There must also be a valve to release the pressure. If the test is a hydrostatic pressure
test, then the pressure release valve must be connected to piping that carries the test
medium to a safe location for disposal.
Figure 14 shows a typical sketch for a test manifold that provides water filling,
pressurizing, flow monitoring, pressure monitoring, and bleed connections. A permanent
pump out connection in another location provides the drain (dewatering) connection for
this particular system; however, the drain connection is often provided by temporary
piping.

Figure 14. Typical sketch for test manifold

Protection of System Components
There are usually components in the system that must be isolated during the test. A
checklist of these components should be provided to the Inspector. He should verify by
visual inspection that all components designated for isolation have been properly
separated from the system.

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INFORMATION

In the case of a hydrostatic pressure test, some parts of the system under test may
require structural reinforcement to support thee additional weight of the test medium.
These parts should be identified on the hydrostatic test diagram. The Inspector must
visually inspect these locations within the system to verify that the additional support has
been properly installed and that it is adequate to support the anticipated loads.
The Inspector visually inspects the source of the test medium to ensure:

That the correct test medium will be provided.

That the correct chemical treatment will be provided if the medium is water.

That the appropriate personal protective equipment will be provided if the

temperature of the test medium is above 49C (120F) or below -66C (-150F).

The Inspector visually inspects all piping components of the system under test to verify:

That all the components are rated for a pressure that meets or exceeds the
pressure specified for the test.

That all pipe flanges, bolts, and gaskets are in serviceable condition.

That new weld joints are properly completed and left exposed (uncoated and uninsulated) for the test.

The Inspector looks for any defective component that might fail even though it is rated at
or above the requirement for the test pressure. He also looks for components that were
installed incorrectly or for situations where a component other than the specified
component has been installed. If the given component is rated below the test pressure,
then that component must be replaced. If it is not replaced, that component becomes the
limiting factor for the test and a new, lower pressure must be specified for the test.

Pressure Gauges, Recorders, and Relief Valves

Pressure Gauges
SAES-A-004 specifies that two or more pressure gauges must be installed to monitor the
pressure during all phases of the test. As a minimum, one pressure gauge must be
located at the discharge of the test pump and one pressure gauge must be located
within the system under test. The inspector verifies that the gauges meet these
requirements:

The gauges must have a range such that the pressure specified for the test is
between 30% and 80% of the full range.

The gauges must indicate within 5% of each other for any given pressure.

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INFORMATION

The gauges must have calibration stickers that indicate calibration within the
past month.

The gauges must have calibration certificates available to document calibration

accuracy.

The gauges must have a block valve and a bleed valve that allow the pressure gauge to
be replaced while the system is pressurized.

A calibration sticker indicates the date a specific pressure gauge was calibrated. Figure
15 shows a calibration sticker.

Figure 15. Typical calibration sticker

Figure 16 shows a calibration certificate that certifies the accuracy of a pressure gauge.
The specific pressure gauge certified by this certificate is identified by the serial number,
MAK-008.
Notice that the calibration range is from 100 psig to 6000 psig. The verification data
section of the certificate indicates that the pressure gauge was checked in three
separate tests. For each test, the gauge was pressurized to a series of known test
pressures and the pressure indication was read and recorded. For all pressures within
the calibration range, the pressure gauge indicated a true pressure and the error was
recorded as zero.

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INFORMATION

FIGURE 5

Figure 16. Typical certificate of calibration

Test Pressure Recorder

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INFORMATION

SAES-A-004 and SAES-L-150 also specify the circumstances under which a pressure
recorder (Figure 17) is necessary for pressure tests:

When it is advisable to keep a permanent record of the test

When test duration will exceed four (4) hours.

When joints are not exposed during the test, such as for buried or insulated
piping. This also applies to partially buried or insulated piping for more than
300m or 10% of its total length whichever is less.

Pressure recorders must also be properly calibrated:

The recorders must have a calibration sticker that indicates calibration within the
past month.

The recorders must have calibration certificates to document calibration.

Figure 18 shows a pressure recorder chart from a 24-hour tightness test. Note that the
chart indicates a leak. The call-outs indicate times of specific events.
Figure 19 shows a pressure recorder chart from a 2-hour strength test. The chart
indicates that there was a failure, necessitating repairs before the system under test
could pass the strength test. When the recorder was started at 10:30 AM on April 6, the
system was already pressurized to 2,000-psi. The callouts on the chart indicate times of
specific events.

Figure 17. Typical pressure recorder

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INFORMATION

Figure 18. Pressure recorder for 24-hr tightness test

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INFORMATION

Figure 19. Pressure recorder for 2-hr tightness test

Test Pressure Relief Valves

SAES-A-004 requires the system under test to be protected by a pressure relief valve
(See Figure 20). The Inspector checks that the pressure relief valve is properly located
at a high point in the system and that the size of the pressure relief valve meets the
requirements of API RP-520. He also checks the tag attached for relief valve test
verification as follows:

The pressure relief setting must be 5% above the specified test pressure.

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INFORMATION

The pressure relief valve must have been tested within the past week.

The date of the relieving test must be clearly indicated on the tag.

Figure 20. Cross-section of a relief valve.

Figure 21 shows a test report for a relief valve. The serial number (S/N) identifies
the specific relief valve tested as TH646990. Notice that the set pressure is 6300
psig. The Final Test Results section of the report shows that the test medium was
water; that the relief pressure was 6300 psig; and the reseat pressure was 5670
psig. The terminology on the report refers to the relief pressure as the Pop Pressure
and the reseat pressure as Tight At. The report contains the signature of the person
performing the test and the date that the test was performed.

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INFORMATION

Figure 21. Test report for a relief valve

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INFORMATION

WITNESS PRESSURE TESTING

Witness System Pressurization
Paragraph 5, Principles of Safe Pressure Testing, of GI 2.102 specifies the requirements
and instructions for filling and pressurizing a system for a hydrostatic pressure test.
Paragraph 5 of GI 2.102 is divided into two sections:

Before Start of Test contains paragraphs 5.1 through 5.12. This section specifies
the requirements for preparation as discussed above.

During and After Test contains paragraphs 5.13 through 5.21. The individual
paragraphs of this section will be explained in detail in the discussion that follows.

Paragraph 5.13 Remove Air before Pressurizing (Liquid Test)

The purpose of this requirement is to reduce the potential for damage should a failure
occur during the strength test. The Inspector must ensure that air is removed from the
system through the vents as the system is filled. For pressure tests of pipelines,
scrapers remove most of the air as the pipe is filled.

Paragraph 5.14 Control Pressure Rise

The requirement for hydrostatic pressure tests specifies that the initial pressure rise may
be 50% of the pressure specified for the strength test. The Inspector holds the pressure
at the 50% level and visually inspects the system. For pneumatic test, the test pressure
is held up at 25 PSI. The Inspector then looks for leaks.
The pressure for hydrostatic tests must be increased in steps of one-fifth the specified
strength test pressure. The Inspector holds the pressure after each rise for a minimum of
ten minutes and visually inspects the system for leaks.

Paragraph 5.16 Restrict Approach to the System

All personnel, including the Inspector, must not approach the equipment while the
pressure is increasing or during the strength test. After the strength test, the pressure
can be reduced to the pressure specified for the tightness test and the Inspector can
make a thorough visual inspection of the system.

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INFORMATION

Witness Strength and Tightness Tests

The Inspector witnesses the strength test by observing the system under test from a
distance as specified in GI 2.102. If the system withstands the test pressure for the
length of time specified by the test procedure, then the Inspector approves the strength
test.
After the strength test is approved, the Inspector allows the pressure to be reduced to
level specified for the tightness test. The system can be approached for a close visual
inspection at this reduced pressure. The Inspector marks any leaks and allows the
system to be depressurized for repairs. After the repairs, the system must be repressurized according to the procedure and visually inspected again. When there are no
leaks, the Inspector approves the tightness test and allows the system to be
depressurized and drained.

Strength Test
Strength tests are given only to new equipment. SAES-A-004 specifies that, for those
new installations that require it, a system strength test must occur after the piping and
equipment are installed in their final positions. The system test pressure must not
exceed the maximum allowable pressure for the weakest component the component
with the lowest pressure rating-included in the test.
The pressure specified for the strength test depends on which part of the system is
limiting the test. For any pressure-containing system, the maximum pressure allowed is
limited by the pipe itself, by one of the piping components, or by a piece of equipment.

Tightness Test
The strength test must be followed by a tightness test for cross-country pipelines, boilers
and for any equipment under pneumatic pressure test. The tightness test is witnessed at
a lower pressure than the strength test. The applicable paragraph from Section 6 of
SAES-A-004 specifies the test pressure for any given tightness test. The test pressure
must be maintained while the Inspector performs a visual inspection of the system to
verify that there are no leaks. The minimum time for any tightness test is ten minutes.
For pneumatic tests, the Inspector uses a soap solution to detect leaks. The Inspector
applies the soap solution to all joints in the system under test. A leak will cause bubbles
to form.

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INFORMATION

Tests of In-service Equipment

The strength and tightness tests are performed on new equipment before the system is
handed over to an operating department. Nevertheless, many situations require
pressure tests of equipment that is already in service. For example, equipment that has
been opened and repaired during a T&I requires pressure tests to verify that there are
no leaks. As with any other test, the Inspector must verify that the correct test pressure
is specified. He uses those requirements from Section 6 of SAES-A-004 that apply for inservice tests.

Witness System Depressurization

Post-test procedures are specified in paragraphs 5.17 through 5.21 of GI 2.102.

Paragraph 5.19 Depressurize Safely

The system should be depressurized through appropriate test manifold. If the system
does not have a safe drain system, then the appropriate temporary piping should be
provided during test preparations.
Systems that contain exchangers and other complex equipment should be
depressurized slowly to prevent internal damage.

Paragraph 5.20 Dispose of Test Media Safely

The test media, including water, may contain chemical additives that may be harmful to
the environment and personnel. Therefore, the test procedure should contain a section
for their proper disposal. The disposal sites for the test fluid shall be reviewed and
approved prior to hydrotest as per SAEP-327. The Inspector ensures that this procedure
is followed.

Paragraph 5.21 Follow Additional Safety Precautions

This paragraph reminds the Inspector of some safety precautions that are critical to a
safe test:

Allow the temperature of the test medium to equalize with the system before
increasing the pressure for the test.

Attend the test pump at all times during the test.

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Isolate the test manifold with a block valve and bleed off the pressure when this
piping is not needed.

Open a vent on any unattended system that has been filled with test medium to
prevent overpressure (or vacuum) due to temperature changes.

Keep the test relief valve installed until the test medium has been drained from the
system.

Drain liquid from a system slowly with the vents open to prevent a vacuum.

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INFORMATION

DOCUMENT THE PRESSURE TEST

Report Strength and Tightness Tests
The Inspector reports the results of the strength and the tightness test by filling in Saudi
Aramco Form 2642-Eng, the Pressure Test Report. An example of this form appears in
Addendum A. When properly completed, this form records the details of the pressure
test:

Data related to the equipment or system tested.

The conditions for the pressure test.

A description of any repairs required to accomplish the pressure test.

The Inspector's remarks concerning the equipment and/or the pressure test.

The Inspector also reports the pressure test on Saudi Aramco form 2093-Eng the
Equipment Inspection Record General. This form is also known as the plant history.
Form 2093-Eng contains a record of all inspections of any kind that have been
performed on the specified equipment. Each piece of equipment used by Saudi Aramco
has its own form 2093-Eng. The Inspector writes a brief statement in the remarks section
that states the pressure test was performed successfully at a given pressure. He may
include any special remarks related to the kinds of repairs required to achieve the
pressure test or and special precautions that were required.

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EXCERCISES

EXERCISE 1.

VERIFY TEST PROCEDURE

Exercise 1A.

Verify Test Procedure: Hydrotest Diagram and

P&ID

By using a hydrotest diagram and a P&ID, this exercise will help you determine whether
a system under test is properly isolated.
Refer to the hydrotest diagram and the P&ID in the Handout. Use the form below to
create a blind list. Has this equipment been properly isolated from the rest of the
system?

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Exercise 1B.

PARTICIPANT

EXCERCISES

Verify Test Procedure: Calculate Test Pressures

You may refer to any appropriate information sheets and/or addenda to complete these
exercises.

1.

Calculate the test pressure for 20" nominal diameter, X-Strong, A-106 Grade B,
carbon steel pipe, operating at 5000 F or less. Show your calculations.

2.

Calculate the test pressure for a Class 150 forged flange, Spec. A-350, Grade
LF3. Show your calculations.

3.

A pressure test will be limited by a 20" NPS Std. pipe, Spec API-5L, Grade X42,
operating at 2000 F or less. The test pressure specified in the hydrostatic test
procedure is 2000 psi. Is this the appropriate test pressure? Show your
calculations.

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Exercise 1C.

PARTICIPANT

EXCERCISES

Verify Correct Gauge

For the following test pressures, state if the correct gauge is utilized and state the
acceptable range of that gauge.

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EXERCISE 2.

PARTICIPANT

EXCERCISES

VERIFY SYSTEM READINESS

Verify Correct Test Pressure Relief Valve(s), Test pressures etc. and witness the
pressure test
This exercise is designed to help you learn and practice the review and visual inspection
techniques required to verify that the correct test pressure relief valve(s) have been
chosen for a specified pressure test. Your instructor will provide you with several
pressure relief valves, pressure gauges. Locate the SIS and the Test Flow Diagram.
Use Work Aid 2A and the applicable standards to verify which relief valves and pressure
gauges comply with Saudi Aramco requirements.
The instructor will arrange for a field trip to witness a pressure test and provide you a
hydrostatic test procedure. Witness the test.

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EXERCISE 3.

PARTICIPANT

EXCERCISES

DOCUMENT PRESSURE TEST

Use your field notes from Exercise 2. Complete the forms and submit to your instructor
for evaluation.

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WORK AID 1.

PARTICIPANT

WORK AIDS

PROCEDURES FOR EVALUATING PRESSURE

TEST PROCEDURE

During the pre-test inspection, the Inspector checks that all aspects of the pressure test
preparation comply with the requirements in GI 2.102, SAES-A-004 and other applicable
standards. He must review the standards, procedures, test diagram and other
documents related to the test. After his review of the test requirements, he must make a
visual inspection of the physical preparations to ensure that each requirement has been
properly met. This Work Aid provides a checklist of the main points that must be
inspected. Some of the items on this checklist are references to more detailed checklists
for specific requirements
1.

Test procedure approved by correct authority. GI 2.102 (5.2) & SAES-A-004

2.

Assignment of responsibility as specified by GI 2.102 (5.1)

3.

Proper test medium (Correct treatment if test medium is water). GI 2.102 (5.3 &
5.4) & SAES-A-004

4.

System under test correctly isolated. SAES-A-004

5.

Test Relief Valve. GI 2.102 (5.5) & SAES-A-004

6.

Test pressure gauges. GI 2.102 (5.5) & SAES-A-004

7.

Drains and vents. GI 2.102 (5.5) & SAES-A-004(4.4 & 4.5)

8.

Test manifold. Gl 2.102 (5.5) & SAES-A-004.

9.

Structural reinforcement. GI 2.102 (5.8) & SAES-A-004

10.

Temporary isolation of equipment not included in the test. Gl 2.102 (5.7) &
SAES-A-004

11.

Verify correct test pressure is specified. SAES-A-004 and applicable standards

as specified in SAES-A-004.

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WORK AID 2.

WORK AIDS

PROCEDURES FOR VERIFYING SYSTEM

READINESS

The requirements for the pressure test preparations for the system under test are
specified by GI 2.102 and SAES-A-004. The Inspector visually inspects the system
under test as follows to verify that these requirements are met:

1.

Review GI 2.102, para. 5.3 - 5.12 and SAES-A-004.

2.

Review the pressure test or hydrostatic test diagram to determine the specified
locations for the drains, vents, test manifold,. temporary support and other
requirements.

3.

Visually inspect for proper location of drains at all low points. Identify dead legs if
they exist.

4.

Visually inspect for proper location of vents at all high points. Identify dead legs if
they exist.

5.

Visually check the relief valve per standards. Refer to Work Aid 2A, Visually
Inspect Test Pressure Relief Valves.

6.

Visually check test pressure gauges per standards. Refer to Work Aid 2B,
Visually Inspect Test Pressure Gauges.

7.

Visually inspect the temporary piping to verify that:

Flush and fill connections meet requirements of Hydrostatic Test Diagram.

Temporary piping that is included in the test has been pre-tested at a test
pressure 20% higher than the specified pressure for the system test.

Drain and de-watering piping meet the requirements of the Hydrostatic

Test Diagram.

8.

Verify proper isolation of all components that are to be excluded from the
pressure test.

9.

Verify all piping and piping components:

Are rated for a pressure that meets or exceeds the test pressure.

Such as flanges, bolts and gaskets are in serviceable condition.

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WORK AIDS

Such as weld joints are properly completed and left exposed to view during
the pressure test.

10.

Verify that the proper test medium has been provided. If the test medium is
water, then verify that all chemical treating requirements have been met.

11.

Verify that all temporary supports have been installed. Visually inspect
these supports for structural integrity.

12.

Verify that appropriate measures have been taken to control access to

the pressure test location during the test.

13.

Notify the Government Affairs Officer of any situation where non-Saudi

Aramco personnel may be exposed during the test.

14.

Verify that work permits will be issued as required to complete the

pressure test.

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PARTICIPANT

Work Aid 2A.

WORK AIDS

Procedures for Visually Inspecting Test

Pressure, Relief Valves, Pressure Gauges,
Witness Pressure Testing And Record The
Results.

Note: This work aid specifies the sub-steps of Step 5 in Work Aid 2.
The requirements for the location of a test pressure relief valve within the system under
test, is specified by GI 2.102 and SAES-A-004.: The Inspector verifies. that these
requirements are met by following this visual inspection procedure:
1.

Review GI 2.102, para. 5.5 and SAES-A-004

2.

Review the pressure test procedure or hydrostatic test diagram to determine the
specified locations for the test pressure relief valve.

3.

Visually inspect for proper location of the relief valve.

4.

Visually check the relief valve tag for:

The correct set pressure - 5% above the pressure specified for the test.

Relief tested within the past week - relief test date should be clearly
marked on the tag.

5.

Visually check the relief valve to ensure that the correct size has been installed in
order to meet the requirements specified for the pressure test.

6.

Verify the pressure gauges:

7.

Have the correct range

Have calibration stickers attached with calibration dates less than 1-month

Indicate within 5% of each other for any given pressure.

Witness system pressurization

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GLOSSARY

GLOSSARY

dead leg

A section of pipe that has no high-point vent or a section of

pipe that has no low-point drain; when the pipe is filled with
liquid, air can be trapped in a dead leg; when a pipe is
drained, liquid can be trapped in a dead leg.

fluid

A term used at Saudi Aramco to mean a combination of

vapor and liquid; for example, a combination of steam and
water is a fluid.

ksi

Kilo pounds per square inch; a unit of pressure. 1 kilo

pound is equal to 1,000 pounds.

medium

The material (liquid or gas) that exerts pressure on a

system for a pressure test; for example, water is a liquid
test medium.

piping, critical

SAES-A-005 defines critical plant piping as

a) piping whose failure leads to a major shutdown of the
plant or a major unit in the plant,
b) piping in high temperature service [340 C (650 F) or
higher],
c) piping under high pressure [3,450 kPa (500 psi) or
greater],
d) piping that carries toxic or corrosive fluids, or e) piping
that has some other specific operating hazard not usually
experienced with usual plant or process lines. Other
standards, such as ASME B31 and SAES-L-100, also
apply.

piping, non-critical

That piping not covered by the definition of critical piping.

piping components

Mechanical elements suitable for joining or assembly into

pressure-tight
fluid-containing
piping
systems.
Components include pipe, tubing, fittings, flanges, gaskets,
bolting, valves, and devices such as expansion joints,
flexible joints, pressure hoses, traps, strainers, in-line
portions of instruments, and separators

PSI

Pounds per square inch; a unit of pressure

57

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GLOSSARY

(to) rupture

To burst; for example, a balloon ruptures when it is filled

with too much air.

thickness minimum

The minimum thickness of metal required to withstand

operating pressures; abbreviated tm, TM, tm or tmin.

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ADDENDUM A: PRESSURE REPORT FORM

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ADDENDUM B: TABLES

Table "Dimensions and Minimum Nozzle Thickness of Seamless and Welded

Steel Pipe"

ASME B31.3, Table A-1

ASME B31.3, Table 302.3.4

ASME B31.3, Table A-1 B

ASME B16.5, Table 1A

ASME B16.5, Table 2

API 5L, Table 4.1

ASME B36.19M Table 2

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ADDENDUM C. HYDROSTATIC TEST PROCEDURE

For Uthmaniyah GOSP-6 Tie-Line

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