SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016) Rev. 2016.06.

00 30-Jun-16
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydro test) SAIC-A-2013 15-Nov-17 MECH.
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

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

Pressure Test Procedure is approved and all safety precautions per SAES-A-004,
A1
GI-0002.102 & SAES-A-007 (Chemical Handling) have been taken. Section 5.8.1

In case multiple water sources or tanker trucks are used to supply

SAES-A-007
A2 water, representative water samples shall be drawn for testing from
Para 6.2.1.2
each source or tanker.

In cases where safety concerns may arise, obtain the approval of the SAES-A-007
A3
General Supervisor, Workplace Environment Division, EPD. Para 7.3.2

During the application of the test pressure, all in-line valves if not
used as test isolation valves shall be in a partially open position*.
Note: A fully open valve can leak at stem packing. Items that interfere SAES-A-004
A4
with filling & Sensitive equipment have been removed from the piping Para 6.1.3
system. System test limits are checked during Inspection walk
down

Approved oxygen scavenger shall only be used as given in Appendix

A. For Dry Gas and Refined Hydrocarbon Product Pipelines, an
oxygen scavenger shall always be added to the hydrostatic test water
as per paragraph 8.4.3, even when the hydrostatic test water contact SAES-A-007
A5
time is less than 14 days.. See Attachment 1 Section 6.1.3
Ensure safe filling of systems with properly
proportioned chemical treatments. See Attachment 1 for these
details.

Filling & pressurization is done upstream of check valves in system.

Test fluid enters (shall be drained) at the lowest point in the system.
All vents are open during filling. Minimize
SAES-A-004
A6 Trapped air. See Attachment 1
Para 6.1.1
(Hydro test Filling & Venting Practices) Quality
Manager & Inspection Action Required for Efficiency

Remove air during filling by the following measures:

A) Design/Plan Tests. Provide high point vents.
B) Mechanically (Use scrapers as
needed to remove air). C)
Follow Attachment 1 regarding Efficiency GI-002.102,
A7
Note: Venting may be accomplished by vent Para. 5.2.2
valves or blind flanges with properly attached test implements
(welded couplings, etc) that are located at the highest point in the
flange to minimize trapped air.

Saudi Aramco: Company General Use

 Vents and drains used only for the pressure test shall be plugged,
seal welded and penetrant tested. Prior to vents seal welding it shall SAES-A-004
A8
be confirmed from proponent for their agreement due to operation Para 7.3
and maintenance purposes.

Procedure requirements are followed step by step:

A) Test Medium is applied as per approved test package
B) Test sequence is controlled. Maximum test
pressure is per approved test package SIS sheet & Pressure Test
Report Form. C) Pressure rise is GI-002.102,
A9 staged (Adequate* hold time between stages) Supplement 1,
D) Inspection & Test Crew follow safety Section 5
responsibilities during test
E) Safeguards (clearance, barricade, signs, permits) are in effect
*10-minute equalization time is an
approximate value used in the GI.

Preliminary check for leaks at 50% of the strength test pressure was
GI-002.102,
A10 performed. Test crews were efficient in filling practices.
Para. 5.2.3
See Attachment 1 regarding Testing Efficiency

Temperature of the water during hydrostatic testing was maintained

well above 60 degrees F (16 C) due to Brittle Fracture consideration
A 17°C Value is listed in 32-SAMSS-004 (Pressure Vessels). This
equals 62.6 F.Note:This should never be a problem in Saudi.
However, air temps can drop to below 10 C & water temperatures will
drop as well. Water temps for Pipeline & Plant Piping testing should
32-SAMSS-004
A11 also follow this minimum remit. Document the "actual" test temps
Para 16.3.13
when low.
Note: On the other end, solar heating can create problems when
testing small diameter piping sections, with difficulty in achieving
successful test results. However, when efficient filling practices are
utilized & tests are well coordinated, this is NEVER a problem.
See Attachment 2.

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016) Rev. 2016.06.00 30-Jun-16
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 15-Nov-17 MECH.
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Final postweld heat treatment shall follow all welding and repairs but
shall be performed prior to any hydrotest or other load test./ All
32-SAMSS-004
required NDE for final acceptance of the vessel shall be performed
A 12 Para 15.6/
after the completion of all welding and repairs and prior to pressure
14.1.3
testing. In vessels requiring PWHT, all NDE for final acceptance shall
be performed after the final PWHT.

REMARKS:

ATTACHMENTS:
Attachment 1 - SAES-A-007 Hydrostatic Test Water Preparation, & Hydrotest Filling & Venting Practices (Efficiency)

Attachment 2 - Efficient Practice For Acceptance of Pressure Tests

REFERENCE DOCUMENTS:
1. SA General Instruction Manual GI-002.102, Pressure Testing Safely, (28 Ocober 2008)
2. SAES-A-004, General Requirements for Pressure Testing, (7 Jan 2016)
3. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures,(24 August 2016)
4. 32-SAMSS-004, Manufacture of Pressure Vessels, (29 June 2015)

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

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

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016) Rev. 2016.06.00 30-Jun-16
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 15-Nov-17 MECH.
Attachment 1 - SAES-A-007 Hydrostatic Test Water Preparation
8 Hydrostatic Test Water Preparation
8.1 Inject oxygen scavenger and other treatment chemicals continuously at a rate that will provide the
specified concentration while filling the system for the hydrostatic test.
8.2 Where multiple treating chemicals are required, ensure that the chemicals proposed for use are
compatible with one another. Use separate proportioning pumps for each chemical to avoid adverse
reactions. Chemicals shall not be mixed* prior to injection. *VERIFY THIS POINT! Check ALL MSDS!
8.3 Monitor chemical injection rates on site using displacement gauges.
10 Safety
10.1 Follow procedures outlined in the Chemical Hazard Bulletins & Hazardous Materials Communications
Program (HAZCOM) labeling provided by the Environmental Compliance Division, Environmental
Protection Department for handling, storage, and mixing of the chemicals to be used for hydrostatic test
water treatment.
10.2 Provide an effective eye wash station/emergency shower per SAES-B-069 at mixing site of chemicals.
10.3 Hydrotests shall avoid the use of biocide during hydrotest itself unless absolutely essential. Lay-up
water may be treated with biocide as necessary.
10.4 See paragraph 4.2.6 concerning water. SEE WARNINGS BELOW!!!
10.5 Hydrotest procedures may involve the displacement of hydrocarbon by fluids, the displacement of
air,
and the use of nitrogen.
10.5.1 Procedures ensure that explosive mixtures of air & gas cannot occur. For example, use of a single
scraper in a pipeline is not sufficient to prevent a dangerous mix occurring between sweet gas and air.
Common practice is to use a train of scrapers with at least 2 batches of nitrogen separating air and gas.
10.5.2 Methanol is a toxic & inflammable chemical & may be used only with adequate safety precautions.
10.5.3 Caution (nitrogen). Not toxic, yet exclusion of breathable air in confined spaces can lead
suffocation.

SAES-A-007 WATER QUALITY WARNING!

4.2.6 Water that could result in harm to humans must not be used for hydrotesting. For example, service
water containing hydrogen sulfide levels that if released to atmosphere would result in air concentrations
of 10 ppm hydrogen sulfide or greater in the immediate area of the hydrotest must not be used. Refer
questions concerning the safety of waters to the Chief Fire Prevention Engineer, Loss Prevention Dept
Hydrotest Filling & Venting Practices (Efficiency)
1. PRESSURE TESTING IS ALWAYS CRITICAL PATH ON MAJOR PROJECTS
2. COMPANY HAS IDENTIFIED PRESSURE TESTING INEFFICIENCY AS A MAJOR OBSTACLE TO
SUCCESS.
3. ROOT CAUSE OF THE INEFFICIENCY IS PRIMARILY POORLY TRAINED TEST CREWS AND
INSPECTORS.
4. QUALITY MANAGERS & THEIR INSPECTORS ARE TASKED TO ASSURE BEST & EFFICIENT
PRACTICES.
5. WHEN POSSIBLE, MULTIPLE TEST PACKAGES ARE COMBINED INTO ONE TEST. DOCUMENT SET-UP.
6. TEST CREWS SHALL ALLOW ADDITIONAL TIME (EFFECTIVELY VERIFIED) FOR TRAPPED AIR TO
VENT.
7. TEST CREWS SHALL PERFORM FINAL FILL SLOWLY AFTER FLUID LEVELS DROP AT OPEN VENTS.
Filling may be done by hand or pump as experience dictates. See Criteria below. Task crews for safety &
efficiency.
Trapped air is usually adequately displaced when a solid flow or stream of water is observed coming out of the
vent.
8. INSPECTION SHALL EVALUATE EFFICIENCY & ASSURE BEST PRACTICES TO MINIMIZE RETESTS.
BACKGROUND INFORMATION: Thousands of Manhours are lost due to test failures (retest required) when
poorly
trained test crews rush during filling. Assure proper venting of air & a slow final fill technique. Efficiency is critical.
Recommendation: Test crews dedicated solely to set-up, filling and other preparation should be utilized.
Training regarding proper filling and venting techniques shall be identified for inefficient test crews who
waste the valuable time of others (Ops, Inspection, SAPMT, PID, etc) when tests fail to hold pressure.

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016) Rev. 2016.06.00 30-Jun-16
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 15-Nov-17 MECH.
CRITERIA: On initial pressurization, pressure holds AFTER equalization at 50% test pressure. Gauge
drops indicate a leak (acceptable for efficiency) or "inefficient" test crews leaving air in lines
(unacceptable). Note: Gauges that hold pressure at 50% of test pressure almost always
pass. Contact SA after lines show a successful result at 50% initial pressurization stage for efficiency.
Communication issue (cell, radio, etc)

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016) Rev. 2016.06.00 30-Jun-16
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 15-Nov-17 MECH.
Attachment 2 - Efficient Practice For Acceptance of Pressure Tests
EFFICIENT TEST PRACTICE (USE TAPE ON GAUGES)
THIS IS FOR ROUTINE PLANT PIPING PRESSURE TESTS (30-MINUTE TESTS) ON SMALL SYSTEMS.
1. PRESSURE TESTING IS ALWAYS CRITICAL PATH ON MAJOR PROJECTS
2. COMPANY HAS IDENTIFIED PRESSURE TESTING INEFFICIENCY AS A MAJOR OBSTACLE TO
SUCCESS.
3. ROOT CAUSE OF THE INEFFICIENCY IS PRIMARILY POORLY TRAINED TEST CREWS AND
INSPECTORS.
4. QUALITY MANAGERS & THEIR INSPECTORS ARE TASKED TO ASSURE BEST & EFFICIENT
PRACTICES.
5. WHEN POSSIBLE, SAVE TIME DURING PRESSURE TESTING SET-UP & PRODUCTION AS FOLLOWS:
a) Ensure Efficient Test Crew Practices as outlined in Attachment 1. Retrain any crews who are inefficient.
b) Minimize time required for Outside Parties (SAPMT, PID, Proponent, etc) to attend Pressure Testing.
c) Implement an easy to perform and easy to document practice of "tape" application on test gauges.
d) Mimimize time waiting on Project Inspection/SAPMT to ABSOLUTE ZERO as follows for 30-minute
tests:
END RESULT WILL BE IMPROVED EFFICIENCY AND LESS TIME ACHIEVING PASSING PRESSURE TESTS.
FOLLOW THESE GENERAL GUIDELINES (DETAILS AS AGREED UPON IN PROJECTS)
1) Notify SA that day (at agreed upon intervals) of the test packages likely to be ready for testing.
2) Notify SA Witness (PMT, PID) exactly when 50% test pressure holds "after equalization". (Cell, Radio)
Technique: QC Inspector has applied a strip of tape (to be later affixed into the test report) on test gauge.
This can be the plain vanilla colored tape approximately 25 mm wide by 50 mm long that allows marking.
The QC Inspector or test crew supervisor match marks the test pressure (on equalization at 50%) and
Verifies the test is ready to proceed to the next stage. Company is informed that their witness is needed.
Note: Any pressure drop indicates liklihood of trapped air or leakage as per Attachment 1 (identify the
cause of the pressure drop BEFORE proceeding, checking valve stems, fittings, valve seat leakby, etc ).
Test reaches 100% of test pressure. Allow adequate equalization time. Note exact start time & notify SA*.
At this time, SA (SAPMT, PID, etc) is notified that the test is ready to begin if they are not already present.
*QC Inspector match marks the pressure gauge needle & writes the start time on the tape (30 minute test).
Note: Usually, only a few minutes are required for most walkdowns. At the test conclusion, the time the
test ended is written down on the tape & the Inspector Initials/Dates/Accepts & affixes tape into test
report.
COMPANY WITNESS ALSO INITIALS/DATES/ACCEPTS TEST ON THE TAPE AFFIXED INTO TEST REPORT.
PACKAGE CONTROL IS CRITICAL FOR EFFICIENCY. LATER, SIGNATURES ARE OBTAINED EASILY LATER
WHEN HARD TAPE EVIDENCE IS AFFIXED INTO TEST REPORTS. IT ELIMINATES THE NEED FOR 100%
SA
PRESENCE AT ALL TEST SITES FOR THE ENTIRE TEST DURATION. ALSO, ON VERBAL APPROVAL,
AFTER
CONFIDENCE IS OBTAINED THAT TECHNIQUE IS EFFICIENT, START TIMES DO NOT WAIT ON COMPANY.
IN ALL CASES, THE TEST IS TERMINATED WHEN INSPECTORS COMPLETE THEIR EXAMINATIONS.
LARGER SYSTEMS, ESP. WHERE CLIMBING IS REQUIRED, REQUIRED COORDINATED INSP EFFORTS.

PRACTICE IS RECOMMENDED FOR PRESSURE TESTING PROCEDURES & IMMEDIATE

IMPLEMENTATION.

Saudi Aramco: Company General Use