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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-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 Test Preparation - General Requirements ... USE SATR-A-2001, 2002, 2003, 2004, 2005 & SATR-A-2006 as req'd.

Pressure Test Package meets Attachment 1 minimum content

requirements. (Reviewed/approved/signed). See SAIC-A-2003. SAEP-1160,
A1 Note 1: Package contents were Section 8
reviewed carefully. Note 2: Document
deficiencies are noted in package for action.
Pre-Test Punchlisting is complete (per procedure). All "A" items are
cleared & accepted* (*Test Pkg Flow Chart is also signed off)
SAEP-1160,
A2 Section 8
Note: "A" items are Pre-test Punchlist items that must be complete
prior to safe pressure testing of systems per approved procedure.

Permanent Flange set installations are documented/accepted.

Note: Flanges that will not
SAEP-1160,
A3 be disturbed after the pressure test are marked/identified and
Section 8
tightened & QC records are per approved procedure & available. See
also SAIC-L-2014 & SATR-L-2001.

System Flushing and internal Cleanliness is complete. Test

SAES-A-004,
A4 Package Flow chart is signed-off. New systems and equipment in
Para. 8.1.2
Plants were cleaned per approved procedures per SAES-L-350.

Component Safeguards (temporary removals/test exclusions) exist

for new systems to prevent damage caused by filling, venting,
SAES-A-004,
draining, flushing or testing. These are itemized on Reinstatement
A5 Section 8
and Pre-Test Checklists and are found in Test Pkgs/Procedures.
See Safeguards listed in Attachment 2.

Temporary supports shall be installed prior to hydrostatic testing, and

SAES-A-004,
A6 flushing of the piping if they were determined to be required per
Para. 8.5.2
SAES-L-150.

Expansion joints and spring hangers or spring supports are provided

SAES-L-150,
A7 with temporary restraints where needed to prevent excessive travel
Para. 6.4
or deformation under the test loads. (Field Verify)

All joints including welded joints are accesible and left exposed for
visual leak detection during the strength test. External coating and SAES-L-150,
A8
priming of such joints are not allowed unless approved. Para. 7.3
Note: This excludes joints subject to 24-hr recorded test

Work permit is obtained for pressure testing and associated work G.I.-2.102,
A9
within restricted areas, as per G.I. 2.100, Work Permit System. Para. 5.1.6

Equipment & appurtenances (Attachments, auxilliary equipment, etc)

that are not adequate for test pressures are isolated from test. G.I.-2.102,
A10
Provisions made to ensure that no over pressuring can occur in Para. 5.1.7
equipment that is not being tested

Saudi Aramco: Company General Use

 If an isolation valve is used for a test boundary, in lieu of test
blind, ensure that no overpressurization damage can occur in any
equipment beyond the isolation valve (due to valve leak-by) by:
a) Reduction of test pressure (rule = G.I.-2.102,
1.1 times valve press rating) b) Open isolation valve Para. 5.1.7,
A11 drain (or nearest adjacent low-point drain) c) SAES-A-004
Relief valves placed on both sides of isolation valve. (Para. 7.3) Para 8.3
d) Personnel are posted during testing to identify any valve
leak-by. e) Personnel control/stop pressurization
(Valve leak-by evidence). See
Remarks Section (Safety Note 1)
MSDS or Chemical Hazard Bulletins is available/reviewed for all
chemicals handled (corrosion inhibitor, bactericide, chlorine, oxygen G.I.-2.102,
A12
scavenger, etc). Written procedure to safely handle chemicals Para. 5.1.9
during testing & to ensure proper disposal after testing is approved.

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SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Personal protective equipment (PPE) is available and utilized as G.I.-2.102,

A 13
shown on these sheets and bulletins for chemical handling. Para. 5.2.1

Access/Egress for Test areas is marked & warning signs posted to G.I.-2.102,
A 14
alert approaching personnel of pressure testing activities. Para. 5.1.11

Where a road parallels within 30 m (100 ft.) of an aboveground

pipeline being tested, traffic shall be diverted or stopped during the G.I.-2.102,
A 15
test. If this is not practical, the area Loss Prevention offices should be Para. 5.1.11
contacted to confirm that the test can be conducted safely.

If non-Saudi Aramco facilities will be exposed in a pressure test of SA

G.I.-2.102,
A 16 facilities, the proponent organization of the test shall so inform the
Para. 5.1.12
Saudi Aramco Affairs representative prior to the test.
Copy of the approved pressure testing procedure & the GI-2.102 are
SAES-A-004,
A 17 available at site. Test Personnel are safety trained/experienced.
Para. 5.6.1

B Verification of Actual Test Set-up & SIS Sheet Data:

Test Set-up* matches actual test arrangement (drawings).

Note 1: *Pressure Test Diagram
with an appropriate Legend for symbols, Test Manifold Arrangement
(& pressure hoses/piping) show all high points (vents), low points
(drains), gage locations & provide documentation that attests to the
SAEP-1160,
actual test as performed. In event of testing accident, Loss
Section 8
B1 Prevention Dept must be able to use diagrams & sketches to
Bullet
recreate actual test set-up/conditions. Note 2:
Item 2
Testing of multiple lines (test pkgs) on projects can be done by
proper hose arrangement, filling & venting to save time. Sketch &
show the actual hose arrangement(s) in test packages. Correct any
errors in arrangement found, initial & date sketches.

SIS Sheet Data (pressure, limiting factor, medium & temperature) is

checked* for accuracy against the test application and is correct. SAEP-1160,
*Note: Human error (test package calcs) is common. Section 8
B2
Inspectors responsible for testing are able to spot gross errors & Bullet
prevent unsafe testing & overpressurization of systems & Item 2
components.

C Test Manifold & Appurtanances (Piping, Fittings, Hoses)

Before employing the pressure testing manifold in the actual system

pressure test, it shall be 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
C1 The test manifold shall be designed and constructed to meet the Para 5.5.4,
minimum system requirements and approved by the Engineering 5.5.4.1, 5.5.4.2
Division head in operating facilities or responsible Project Inspection
Division head in new construction.
Test manifolds shall have 100% NDT of all welds.

Pressure rating or design of test manifold components* (isolation

valves, pipe nipples, fittings) exceed system test pressure by 20%. G.I.-2.102,
C2
See Safety Note 1 in Remarks for isolation Para. 5.1.5.5
valves

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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Manifold Arrangement Drawings attest to the following:
A) Fabrication was per code construction with component
details listed such as Class, size, schedule, type isolation valve, etc.
B) Maximum Safe Test
Pressure Rating based on limiting factor. C)
G.I.-2.102,
C3 Each test manifold is identified with a unique number (certificate)
Para. 5.1.2.5
D) Shows actual arrangement including hose
configuration used Note 1:
Manifold permanent marking (unique ID #, pressure rating) is legible,
traceable & certified (Engineering support docs).

Manifolds proposed for use on projects without detailed code

construction certification (Engineering calcs & Inspection) must be
evaluated for fitness and safety. Provide necessary details and
G.I.-2.102,
C4 support test manifolds with any necessary calculations (SIS sheet)
Para. 5.1.5.5
and the appropriate visual Inspection and any necessary NDE.
Note: Unknown piping schedules can be determined by
using a UT Thickness meter. Weld quality is verified by VT or RT.

A blow down valve of adequate pressure rating is installed to G.I.-2.102,

C5
depressurize the system safely (easily accessible to operator). Para. 5.1.5.3

Test Manifold pressure tested to at least 20 percent above test

pressure of the system under test. (Exception: Final connection
between test manifold and system under test may be tested to G.I.-2.102,
C6
maximum system test pressure only if a higher test pressure is Section 5.1.5.5
impractical.) The test manifold test certificate shows the limiting factor
(lowest pressure rated component).

Paddles or spectacle blinds & other fabricated test items used to

isolate test sections are at least the same code class rating of SAES-A-004
C7
systems under test or are supported by appropriate code calcs. See Para. 8.3
Remarks, Critical Safety Note 2

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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
D Test Relief Valve(s)

Relief valve is located in the system under test and near the test
G.I.-2.102,
D1 pump with Isolation valves on the inlet and outlet of the relief valve
Para. 5.1.5.1
sealed open during the test. (SAEP-1160, Bullet Item # 3)

Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available)

are set to relieve at 5%* above the hydrotest pressure. SAES-A-004
D2
*Note: Test pressures less than 85% of SMYS can have Para 5.5.1
relief valves set at 10% above test pressure. Verify SIS sheets calcs.

Relief valve(s) are tested, dated, and tagged (as valid) for a period of SAES-A-004
D3
one week for project pressure tests. Stickers are legible & valid. Para 5.5.1

E Pressure Gages and Recorders

A minimum of two pressure gages are required for test systems, with
accuracy within 5% of one another.
Note 1: When large systems are tested, Inspection personnel will
determine the need for additional gages.
Note 2: Elevation changes (hydrostatic head SAES-A-004
E1
considerations) & hot weather create pressure testing problems with Para 8.1.5.4
frequent popping of relief valves. For this reason, gage accuracy
within 2% is best. Note 3: Careful handling of
delicate instruments like test gages is practiced by test crews. No
gage damage or mishandling is found.

Pressure gages and pressure recorders are calibrated within (1) SAES-A-004
E2
month prior to test. Stickers applied indicate latest calibration date. Para 8.1.5.2

G.I.-2.102,
Avoid the following typical examples of poor practices:Testing
Sec.4 &
E3 equipment with the test gauge located at the bottom of the equipment
SAES-A-004,
reading the test pressure,including the head of test water
Para 5.3
All gages have a range such that the test pressure is within 30% to SAES-A-004
E4
80% of the full range. Para 8.1.5.3

F Temperature Gages and Recorders (When Required, ie: 24-hr Recorded Tests)

Bubble Leak Test (associated with Pneumatic strength/service test)

surface metal temperatures shall be recorded and compatible with
test methods (including test solution used to detect leaks).
SAES-A-004
F1 Note: ASME V, Art 10, Man. App. 1, Table 1-1021
Para 5.6.3
requires surface metal temp measurements during testing (detailed
in procedure). Record maximum (direct sun) & minimum test
temperatures.

Thermocouples are installed to obtain accurate pipe metal

temperature measurements and to determine the acceptance of the SAES-L-150,
F2
pressure test where pressure variations due to test water Para. 11.3
temperature changes occur, such as in cross-country pipelines.

REMARKS: Critical Safety Note 1: Surveys of test manifolds used on projects have resulted in many findings of inadequate ratings for isolation
valves. Test manifolds for testing specific pressure rating Classes require isolation valves of the next higher class. Example: Manifolds for testing
Class 300 # systems require Class 600 # isolation valves as a general rule. For Pressure tests against closed seats follow the 110% rule for safe
test pressure calculation. See ASME B16.34, Para 7.2 as applicable. Also, this same requirement must be carefully considered when determining
test pressures where an isolation valve serves as a test boundary limit and the valve seat will be pressurized. Ensure system test pressures are
reduced to 110% as applicable and show the valve seat as the test "limiting factor". Safety Note 2: Fabricated test
implements of proper code construction receive inspection and properly identification/marking for pressure rating, inspection acceptance/fitness
(Insp Ok, initial, date). Never allow uninspected non-code test implement use or those that are unfit for testing (deteriorated, damaged, heavily
corroded). Unsafe/unfit test implements found are reported/removed ASAP from Company Projects.

REFERENCE DOCUMENTS:
1. SAES-A-004, General Requirements for Pressure Testing, (30-Jan-2011)

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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Pressure Test Preparation SAIC-A-2011 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely, (28 October, 2008)
3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (24-Dec-2014)
4. Pro Forma Contract Schedule Q (Project Specific)
5. SAEP-1160-- Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects (10-July-2011)

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

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Attachment 1 - SAEP-1160 Test Pkg Minimum Requirements

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Attachment 2 - Component Safeguard Summary
Note: This Summary Checklist has been developed with concurrence of CSD
1. INSTALL THESE COMPONENTS IN LINE ONLY AFTER THOROUGH FLUSHING:

Soft seated valves & control valves (SAES-A-004, Para. 8.1.3)

2. INSTALL THESE COMPONENTS IN LINE AFTER FLUSHING & TEST COMPLETION (ON
REINSTATEMENT):
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. This includes Procedures/Test Package Instruction or details about specific
component care as listed below (SAES-A-004, Para 8.1.4):
a) Orifice plates -- Flow nozzles -- Sight glasses (incl. vessel trim) -- Venturies -- Meters (positive displacement,
turbine)
b) In-line equipment (as determined by Proponent) includes valve care (corrosion, cleaning, lay-up considerations). A list
shall be obtained by Contractor from COMPANY relative to Component Safeguards. Contractor shall request specific
instruction for specific component safeguards from Company (Proponent, SAPMT, SA Inspection)
3. INSTALL THESE COMPONENTS (EXCLUDED FROM PRESSURE TEST) ON FINAL REINSTATEMENT:
Note: The following list defines the equipment that shall be excluded from the in-situ pressure
testing of the tested system. Also, other unlisted sensitive equipment or as designated by SA Inspector can be added (SAES-A-
004-Para 8.2):
a) Rotating machinery, such as pumps, turbines and compressors;
b) Strainers and filter elements
c) Pressure relieving devices, such as rupture disks and pressure relief valves;
d) Locally mounted indicating pressure gauges, where the test pressure will exceed their scale range;
e) Equipment that cannot be drained (This includes valve cavities. See Valve Care below).
f) Instrument Devices.
g) Other unlisted sensitive equipment (propose exclusion in test package)
h) Equipment designated by Saudi Aramco Inspector (Approves procedures that list specific equipment in scope)
CSD VALVE SAFEGUARDS & CARE (TYPICAL FOR AMBIENT LAY-UP)
Valve Field Hydrotest Practice (separate from line/system testing) assures adequate preservation as listed below. Valves
or other equipment that are field tested prior to installation in a pipeline, plant, or other facility are likely to experience corrosion
damage if this is not performed with adequate diligence and precautions.
a) The following applies to valve trims Type 1, 4, 6, 7, 8, and 8A and all solid Type 400 SS (13 CR) valves.
b) Plan prior field testing of valves to minimize the length of time between test and installation in the system.
c) All critical isolation valves that are tested shall be tested with water containing less than 50 ppm chlorides. The water shall
contain 0.5% by weight (5 grams per liter) Cortec VpCI 609. (Note:Chemical cost would be about $0.30 per liter. VpCI 609 is
biodegradable so there are no problems with its use. (See Environmental Protection Dept.)
d) After hydrotesting, gate valves will have their gates raised to allow full draining of water. Allow adequate drainage time. All
traces of visible
e) Apply water shall
manufacturer be removed
approved from
lubricant the10%
plus valve bodyVpCI-329
Cortec and seat area.
(SAP Blow dry with clean
1000173887) addedcompressed
to all interiorair.
critical surfaces
such as seal areas. Ball valves shall be full operated to distribute inhibited lubricant between ball and body.

Constructed Piping Hydrotest Practice (Valve Safeguards)

a) Hydrotest plans for constructed field equipment shall be designed to minimize exposure of valves to hydrotest water. Unless
it is absolutely unavoidable, critical isolation valves (Field Hydrotested) shall be installed after completion of hydro.
b) Piping systems shall be thoroughly flushed before hydrotesting to remove wind-blown sand, construction debris, and any
other foreign matter. Flushing water shall be the same quality as the hydrotest water. Hydrotest shall be performed
immediately after flushing or the line shall be properly layed-up per SAES-A-007 Procedures (30-day rule).
c) If any 400 series (13 CR) trimmed valves are pre-installed & hydrotested in the line, utilize test gaskets and thoroughly drain
test water immediately after the test. Where complete draining is impossible (no valve body drain plug), valves shall be
removed immediately after test, dried with clean compressed air and re-lubricated before "ambient" lay-up. Ensure
that there is no debris in the seat area.
d) Any 400 series (13 CR) trimmed valves that are pre-installed and hydrotested in the line, and that have body or seat drains
and are in place when field pipework is hydrotested shall be treated with Cortec VpCI 609 by blowing into all possible valve
injection locations immediately after completion of the hydrotest and draining of all water.
e) Any 400 series (13Cr) trimmed valves that are pre-installed welded-in-place shall be liberally coated with inhibited lubricant
before final welding into the line.
f) Safeguards for 300 series (316 SS, etc) trimmed valves require similar care to assure complete cavity draining. Corrosion
inhibitors used shall be approved by CSD.
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