SAUDI ARAMCO ID/PIEU -3- July-2018 - REV. 2018.04.00 (Standards Cutoff -April 30, 2018) Rev. 2018.04.

00 30-Apr-18

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Inspection of Filling & Pressurization (Hydro test) SAIC-A-2013 3-Jul-18 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 GI- SAES-A-004,
A1
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 water,
SAES-A-007 Para
A2 representative water samples shall be drawn for testing from each source
6.2.1.2
or tanker.

In cases where safety concerns may arise, obtain the approval of the SAES-A-007 Para
A3
General Supervisor, Workplace Environment Division, EPD. 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
SAES-A-004 Para
A4 open valve can leak at stem packing. Items that interfere with filling &
6.1.3
Sensitive equipment have been removed from the piping 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
SAES-A-007
A5 paragraph 8.4.3, even when the hydrostatic test water contact time is less
Section 6.1.3
than 14 days.. See Attachment 1
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 Trapped air.
SAES-A-004 Para
A6 See Attachment 1 (Hydro test Filling &
6.1.1
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
GI-002.102,
A7 Attachment 1 regarding Efficiency
Para. 5.2.2
Note: Venting may be accomplished by vent 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.

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

Saudi Aramco: Company General Use

 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.
GI-002.102,
C) Pressure rise is staged (Adequate* hold
A9 Supplement 1,
time between stages) D)
Section 5
Inspection & Test Crew follow safety 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 also follow this minimum remit. 32-SAMSS-004
A11
Document the "actual" test temps when low. Para 16.3.13
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.

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SAUDI ARAMCO ID/PIEU -3- July-2018 - REV. 2018.04.00 (Standards Cutoff -April 30, 2018) Rev. 2018.04.00 30-Apr-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 3-Jul-18 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 -3- July-2018 - REV. 2018.04.00 (Standards Cutoff -April 30, 2018) Rev. 2018.04.00 30-Apr-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 3-Jul-18 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 -3- July-2018 - REV. 2018.04.00 (Standards Cutoff -April 30, 2018) Rev. 2018.04.00 30-Apr-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 3-Jul-18 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