SATIP a 004 02 Hydrostatic of on Plot Piping

-

ev

SAUDI ARAMCO TYPICAL INSPECTION PLAN Hydrostatic Testing of On-Plot Piping

SATIP No.

PROJECT TITLE:

WBS/BI/JO/NO.

ITEM NO.

PROJECT PHASE & Activity Code

1.0

DOC REVIEW

TASK / ACTIVITY

QUALITY PROCEDURE

APPROVED DATE

DISCIPLINE:

SATIP-A-004-02

QUALITY RECORD

MECHANICAL CONTRACTOR/SUBCONTRACTOR

INSPECTION RESPONSIBILITY ASSIGNMENTS CNTRCTR

REMARKS

SAUDI ARAMCO

SPECIAL PROCESS (PRESSURE TESTING) REQUIRES BEST QUALITY PRACTICE, PRACTICE, CPI & EFFICIENT METHODS IN PROCEDURES. PROPOSE BEST METHODS.

1.1

Hydrostatic Testing Procedure

SAIC-A-2001

SAIC-A-2001

RH

RH

Submit Sample Test Pkg & Procedure together

1.2

Revi Review ew of Test Test Pack Packag age e Prep Prepar arat atio ion n

SAIC SAIC-A -A-2 -200 003 3

SAIC-A-2003

RH

R*

Submit Sample Test Package & Pressure Testing Procedure together, *See Notes 1 & 6

1.3

Re-Instatement Procedure

SAIC-A-2006

SAIC-A-2006

RH

RH

Required Per SAEP-1160, Section 8

1.4

Lay-Up Procedure

SAIC-A-2007

SAIC-A-2007

RH

RH

1.5

Line Flushing or Internal Cleanliness Procedure

SAIC-L-2001

SAIC-L-2001

RH

RH

This is in conjunction with SATIP-L-350-01 or the applicable piping/equipment SATIP.

Verification of Testing Media for Hydrostatic Testing (Water Quality)

SAIC-A-2008

SAIC-A-2008

RH

R

Use SATR-A-2014 & Utilize SAIC-A-007 reqmts

3.1

Pre-Test Punch Listing

SAIC-A-2010

SAIC-A-2010

H

H

Use SATR-A-2007 In Conjunction with applicable piping/equip SATIP

3.2

Intern al al Clea nl nlin es ess an d/ d/or Flu sh shin g

SAIC-L-20 17 17

SAIC-L-20 17 17

H

H

Use SATR-A-2008 In Conjunction with applicable piping/equip SATIP

3.3

Verification of Testing equipment (including safety reqmts)

S AI AI CC- AA- 20 20 09 09

S AI AI CC- AA- 20 20 09 09

H

W

Safety Assessment can be performed along with SAIC-A-2011. Use SATR-A-2001 SATR-A-2002 SATR-A-2003 SATR-A-2004 SATR-A-2005 SATR-A-2005 SATR-A-2006 Forms SATR-A-2003 & SATR-A-2004 shall be used for 24hr recorded hydrostatic test on UG piping or piping with joints covered before test.

2.0

MAT'L RECV

2.1 3 .0 .0

APPLICATION

3.4

Verification of Test Preparation

SAIC-A-2011

SAIC-A-2011

H

W

3.5

Filling & Pressurization

SAIC-A-2013

SAIC-A-2013

W

S

3.6

Visual I ns nspe ct ction a t Te Test Pr Pressu re re

SAIC-A-201 5

SAIC-A-2015

H

H

Use SATR-A-2001

3.7

Pneumatic Testing of Reinforcing pads covering Pressure containing Welds

SAIC-A-2016

SAIC-A-2016

W

W

Use SATR-A-2010, SAIC-A-2021, SAIC-A-2023

3.8

De-Pressurization & W ater Disposal

SAIC-A-2017

SAIC-A-2017

W

S

Page 1 of 2

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ev

SAUDI ARAMCO TYPICAL INSPECTION PLAN Hydrostatic Testing of On-Plot Piping

SATIP No.

PROJECT TITLE:

WBS/BI/JO/NO.

4.0

APPROVED DATE

DISCIPLINE:

SATIP-A-004-02

MECHANICAL CONTRACTOR/SUBCONTRACTOR

POST- TEST

4.1

Water Removal from Valve Cavities, Corrosion Control after Testing (In-line Tested Valves)

SAIC-L-20 41 41

SAIC-L-20 41 41

W

W

Use SATR-A-2001V & SAIC-L-2042 Demonstrate effective preservation/corrosion control in conjunction with approved cleaning & lay-up procedures for valves tested in the line.

4.2

LayLay-Up Up Inspe Inspect ction ion

SAIC SAIC-A -A-2 -2018 018

SAIC SAIC-A -A-2 -2018 018

H

W

Use SATR-A-2009 & SATR-A-2014

H

Complete SATR-A-2007, Use SATR-A-2011 & SATR-A-6133 - Verify Reinstatement Completion & Certify Test Pkg. Transfer Incomplete items to 6133 Feil for Piping System close-out.

4.3

Re-Instatement Inspection

SAIC-A-2006

SAIC-A-2006

H

GENERAL NOTES 1

The first three incidents of each Inspection or testing activity listed require 100 % participation by Saudi Aramco Site Inspection Personnel. After this period, Saudi Aramco Inspection may adjust the levels of Saudi Aramco participation based upon the Contractor’s performance.

2

Surveillance: QA/QC organization to monitor work in progress without notice from Construction Organization.

3

Witness: QA/QC organization shall be notified of the timing of Inspection or test in advance. However, the inspection or test shall be performed as scheduled if the QA/QC organization representative is not present.

4

Hold: QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test shall not be carried out without the QA/QC organization representative in attendance.

5

If the Main Contractor delegates the assigned responsibility to the Subcontractor, then the Main Contractor will have the same degree of responsibility as assigned to Saudi Aramco.

6

For Test Package Preparation & review on large projects, each new system designed for testing is thoroughly reviewed & approved. All subsequent packages within a given system shall be built following the "Copy & Paste" theme for Test Package efficiency and then R1 (Contractor) & R2 (Company Sample Review of documents) Inspection may be performed.

H

100% Hold Point for QC Inspection or Test.

W

W itness Inspection/Test

LEGEND R RH

Review of Documents Review and Approval of Documents

Page 2 of 2

SAUDI ARAMCO ID/PID - REV 0- 18-May-05 (Standards Cutoff -June 2008)

Rev 3 SAIC NUMBER

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Review Procedure - Pressure Testing (All Applications) PROJECT TITLE

SAIC-A-2001 W BS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

CONTRACTOR INSPECTION LEVEL

A

A1

SYSTEM ID.

ACCEPTANCE CRITERIA

REFERENCE

MH's SPENT

Sch Q, Para 3.1

A2

A) An approval section exists to document adequacy adequacy prior to use. B) Revision control section exists to document procedure changes. (ISO 9001:2000, Para. 4.2.3a)

Sch Q, Para 3.1

A3

An attachment section exists exists listing applicable QC forms & records. records. (ISO 9001:2000, Para. 4.2.4a)

Sch Q, Para 3.1

A4

Other sections for special process control procedures (per Sch Q) detail references, responsibilities, definitions & procedure reqmts.

Sch Q, Para 3.1

A5

Special Process Procedure includes details of Data Mgmt & Tracking system used for tracking/reporting & the responsibility for following: A) Production welds (full pen groove welds*), welds*), welder performance, performance, NDE, PMI, PWHT, BHT & other applicable tests (Ferrite Content, etc) B) Can identify weld repairs & modifications after acceptance and any need for follow-up pressure testing or NDT. Also, backlogs. C) Detailed steps for Pressure testing package co-ordination with above items (controls) and pressure testing reporting requirements. Contractor shall record & track production, inspection & testing of socket & fillet welds in separate database submitted weekly to COMPANY.

S-PM-G000-15200006 Sec. 8

Page 1 of 20

TRAVEL TIME

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)

Procedure is project specific, identifiable by Budget Item (BI) or Job Number, Contract Number & Project title & traceable to Quality Plan.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP.

SAUDI ARAMCO INSPECTION LEVEL

MECH-

CONTRACTOR / SUBCONTRACTOR

PURCHASE ORDER NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

QR NUMBER

22-Jan-14

EQPT CODE

SAUDI ARAMCO TIP NUMBER

ITEM No.

30-Jun-08 DATE APPROVED

RE-INSP DATE


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Pressure Testing (All Applications) PROJECT TITLE

ITEM No.

SAIC NUMBER

SAIC-A-2001 WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE


22-Jan-14

PASS

FAIL

B

B1

Procedure lists Pressure Test Package contents as follows: ( 1 ) Reference the "Approved" Pressure Test Procedure ( 2 ) Pressure Test Diagram which shall include the limits of piping (including test manifold) and equipment included in each pressure test, high points and low points (drain), locations of pressure gauges, test pressures, test temperature, test fluid, line flushing requirements, and safety precautions ( 3 ) Relief valve capacity, testing and installation ( 4 ) Pressure gages and recorders calibration records ( 5 ) COMPANY Safety Instruction Sheet (for critical piping) and Pressure Test Report Form ( 6 ) Copies of P&ID and isometric drawings of the piping system to be pressure tested ( 7 ) Piping spools control sheet with NDT extent and results. ( 8 ) Pre-pressure test check List ( 9 ) Re-instatement procedure and Check List ( 10 ) Flange set completion documentation for permanent installations ( 11 ) Identification of pressure testing SPC from CONTRACTOR ( 12 ) Lay-up method to be applied ( 13 ) Verification of chemical dosing calculations when applicable ( 14 ) Test manifold hydro test verification

B2

Procedure (elements) detail GI-2.102 reqmts as follows: • Pressure Test Diagrams (Use of Test Symbol Legend) • Test manifold arrangement (GI-2.102 Att. 1 Sect. 5, SAIC-A-2009) • Location of blind flanges & isolation valves • Check Valve & sensitive instrument/equipment disposition • Test limiting factor determination (SIS sheet/Component review) • Location of test vents, fill points and drains • Relief Valve capacity, quantity, sizes and set pressure adequacy • Test medium (water, treated water, lube oil, etc) and cleanliness • Test pressure duration and limitations • Special support requirements • Test sequence (Controlled/staged pressure rise, 10-minute holds) • Detailed Inspection & Test Crew responsibilities during testing • Safeguards (Personnel clearance, Barricades, signs, permits) • Staged and safe filling, venting and disposal practices • Additional personnel & Equipment (radio, signals) used for tests • Safety Instruction Sheets (Completion & Review Responsibility)

GI-2.102 Attachment 1 Section 2

B3

Procedure Equipment section details requirements as listed: • Relief Valve is tested/tagged with set pressure/date (7 Days rule) • Relief valve has adequate capacity (multiple relief for volume test) • No block valves exist in the relief valve inlet or outlet • Relief valve is located near test pump or medium supply • Two or more calibrated pressure gauges are used (30 day rule) • Pressure gauges are properly located with block/bleed valves • Pressure gages at pump or supply are clearly visible to operator • Blowdown & Isolation valves exist on the test piping • Blowdown areas are designated for safety (Warning signs) • Manifold is certified/tested to 1.2 times m aximum test pressure.

GI-002.102, Attachment 1, Section 5 See Note 2 & SAIC-A-2009 / S-PM-G0001520-0007 Sec 6.4

Page 2 of 20

MECH-


General Requirements Note 1: Use SAIC-A-2003 for specific Test package responsibilities & instructions Note 2: Use SAIC-A-2009 for specific Testing Equ ipment requirements including Safety Inspections

S-PM-G0001520-0006 Sec. 10

QR NUMBER

N/A

RE-INSP DATE


Rev 3


ITEM No.

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

B4

Procedures for both hydrotests and service tests address safety precautions provided in GI-0002.102 "Pressure Testing Safely". Procedure states: A copy of GI-2.102 and the approved pressure testing procedure shall be kept at test sites. Test crews and those personnel responsible for pressure testing are trained and aware of GI and procedural requirements to assure safe pressure testing

S-PM-G0001520-0007 Sec6.5.1

B5

Procedure states: Hydrostatic tests are scheduled as close as possible to start-up date with minimal time between introducing test water & commissioning the equipment. Hydrostatic tests and lay-up procedure shall be designed to protect corrosion-susceptible matls. Inspection strategies & plans are prepared and agreed on prior to commencing fabrication and erection. System testing & lay-up considerations shall be addressed.

S-PM-G000114Z-0003, Sec-6.2

B6

Definitions of various types of pressure tests are listed: A) Hydrostatic Test, Leak Test, Pneumatic Test, Revalidation Test, Service Test, Strength Test, Tightness Test. B) If Valve Field Testing is included in procedure (see API 598), add: Valve Shell Test, High-Pressure Closure Test, Low-pressure Closure Test & Backseat Test. Procedure clearly states differences between test types

S-PM-G0001360-0001, Sec-2

C

C1


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

Pipeline Pressure Testing Applications ( Include in pr ocedure if applicable per s cope) Pipeline Strength Tests for New Pipelines are detailed in procedure and conducted as follows: A) Strength Test pressure is limited by flanges or valves in the line. B) Strength Test pressure is calculated. Hoop Stress (HS) at 90% of Specified Minimum Yield Strength (SMYS) of pipe's nominal wall. C) Strength Test pressure at low point considers static head D) Strength test temperature stresses are not above SMYS. E) Strength test pressure is maintained for two hours.

SAES-L-150, Section 8

Procedure details calculation checks and responsibilites

C2

Pipeline Tightness Test is conducted at 95% strength test pressure immediately after completion of strength test: A) The tightness test pressure is maintained as long as required for the inspector to examine all exposed joints. B) A 24-hour recorded tightness test is done when a pipeline is buried/insulated, or partially buried/insulated for more than 300 m or 10% of its total length, whichever is less.


Procedure details Tightness Test parameters

C3

Revalidation Pressure Tests for Existing Pipelines are detailed in procedure and calculations are checked as follows: A) Test pressure is determined (as applicable) as follows: • minimum of 1.25 times MAOP (with 0.6 & 0.72 design factors) • minimum of 1.4 times MAOP (with 0.4 and 0.5 design factors) B) Actual wall thickness & flange rating determines test pressure.


Work i s per latest edition of SA E P-310 requirements for the Repair & Maintenance of Pi pelines .

C4

Procedure details: Valve Field Pressure Test Applications, Test Facility, & considerations before, during, and after testing:

D

On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)

Page 3 of 20

See item D4 below

RE-INSP DATE


Rev 3


ITEM No.

D1

D3


ACCEPTANCE CRITERIA

REFERENCE

Procedure has an On-Plot Piping Pressure Testing Matrix. See Attachment 1. This shall cover all tests for On-Plot activities and, when reviewed with the Pressure Testing Specification, shall provide adequate instruction for Test Package Development & On-Plot pressure testing & other related testing activities including all Utilities (sewer, water), Firewater & Plumbing systems.

Pr ovide clear On-P lot test boundaries & test reqmts.

D2

SAIC NUMBER

Procedure states: A hydrostatic strength test shall be applied to all newly constructed plant piping prior to initial operation per the applicable COMPANY requirements and ASME B31.3 or ASME B31.1 except as noted. (Detail Exceptions in procedure)

Define Test Workscope & Specifications Sch Q, Att IV, Table 2.1

S-PM-G0001360-0001, Sec23.2

Procedure details: Valve Pressure Test Applications, Test Facility, & considerations before, during, and after testing: A) Applications include Field hydrotesting per SAIC-L-2042 that follow SAES-L-150, SAES-L-108, API 598, & ASME B16.34 requirements. Valves require Section 5.11 / body & seat closure tests per SAES-L-108, Sect. 4. S-PM-G000B) Valve Testing Facility meets SAIC-L-2031 (See Sections D & J). 1360-0001, SecC) In-line testing of valves (body test, seat test restrictions & calcs) 23.11 D) Post Test draining, cleaning, inspection and preservation details shall & SAES-L-108, be included whenever valves without drains are tested in-line. Section 4.7

Valve Testing is included in press ure tes ting procedure. See Att 2 (AP I 598 Definitions, C onsiderations for Tests ag ainst Valve Seats, Pos t-Test Valve cavity cleaning & ins pection)

D4

S-PM-G000Sampling piping systems are pressure tested as an integral part of the 1360-0001, Secpiping or equipment to which it is connected. 23.5

D5

S-PM-G000Lube and seal oil piping is strength tested in its own fluid at the greater 1360-0001, Secof 1.5 times design pressure or 100 psig ( ≥ 30 minutes). 23.17 a

D6

D7

D8

Underground process plant piping is tested as follows: A) Prior to any backfilling for 30 Min. minimum (Check 100% joints) B) If back-filling is required for safety, there are two options: • 100% of weld joints remain fully exposed during the 2 hour test • 24-hour recorded test is performed if any weld joint is buried For jacketed piping, the internal line shall be hydrotested according to paragraph 7.1. All field welds shall be visible for leak detection during the hydrotest. The jacket shall be hydrotested according to ASME B31.3. The maximum allowable external pressure for the internal line shall not be exceeded during the jacket pressure test. The differential pressure can be minimized by pressurizing the internal line.

S-PM-G0001360-0001, Sec-23.17 b

SAES-L-150 Para 7.4

Tie-In butt welds are detailed in hydrotest procedure as follows: A) Tie-in butt welds (to new or existing pipe) are Pressure tested S-PM-G000B) Test Pressure is based on minimum Code requirements if the tie-in is 1360-0001, Secto an existing system. 23.6 C) If a Pressure test is deemed impractical, it can be substituted with a request of NDT in lieu of pressure testing as processed.

Page 4 of 20


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3


ITEM No.

D9

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

Instrument impulse lines are hydrotested only as follows: A) Liquid test is performed when the test pressure is greater than 1000 psig. Air or nitrogen use is allowed up to 1000 psig. B) Between root isolation valve & instrument isolation using treated water (or approved fluid) at 1.25 times system design pressure. C) The test duration is not less than 30 minutes. D) Instrumentation subject to damage from testing is disconnected. E) When liquid is used in lieu of air, lines are blown dry after test.

SAES-L-150, Para 5.12

S ee Attachment 2 for related Flus hing /Cleaning Methods

D10

RETESTING of Piping systems that have already successfully passed a pressure test require a second pressure test if/when: A) Major Repair of Piping system subject to new welding activity. Note: This includes modifications & pressure boundary work. B) Post-weld Heat Treatment (PWHT) is specified for that line. Note: Seal welded threaded connections, non-pressure containing welds to attachments (wear pads, etc) are exempt from retesting unless the line is specified for PWHT.

S-PM-G0001360-0001, Sec-23.8

Procedure details retesting reqmts & responsi bilities, and the Database has capability for tracking such repairs.

D11

Open-ended Piping (drains, vents & piping downstream of PZVs) discharging directly to atmosphere (max internal pressure 10 psig) is not pressure tested. Test Package lists "Visual exam only".

S-PM-G0001360-0001, Sec-23.9

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060) are detailed in procedure as follows: A) Test entire hot or cold water supply system (test & prove tight) under a water pressure of 1034 kPa (150 psig) for 4 hrs minimum. Note 1: Test all piping within building from building isolation valve. Note 2: Water distribution piping network (utility piping from tankage) to building isolation valve & connected fire hydrants are tested at 150 psig or 50 psig above maximum operating pressure, whichever is greater.

Newly constructed water supply systems are disinfected per GI0151.006, S A S anitary C ode, C hapter S AS C-S -01. The procedure D12 covers this as part of preparation (treatment) B) Service Test (Check for leaks) shall be performed on all new equipment connected to water supply lines such as W ater Heaters, Drinking Fountains, etc. that are isolated from the 150 psi test.6.3 Testing, Inspection and Backfilling Gravity sanitary sewers, gravity sanitary sewer manholes and sanitary sewer force mains shall be hydrostatically tested, inspected, repaired and backfilled in accordance with SAES-S-070. 8-2.2 (Addition) Disposal of water used for flushing and testing the piping system shall be in accordance with GI-0432.000. (rescinded)

Page 5 of 20

SAES-S-060, Para. 103.5.3.3


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3


ITEM No.

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-S070, SATIP-S-020) are detailed in procedure as follows: A) Test entire hot or cold water supply system (test & prove tight) under a water pressure of 1034 kPa (150 psig) for 4 hrs minimum. B) Test Gas Systems (welds & j oints accessible) with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not less than 1-½ times SAES-S-060, maximum working pressure, but not less than 60 psi (413kPa) for a Para. period of not less than thirty (30) minutes. D13 C) A low pressure air test not exceeding 345 kPa (50 psig), & soap 103.5.3.3, bubble test shall be used to test sanitary drainage or plumbing system of Para 1204.3.2, any building premises when there is reason to believe that it has become Para. 103.5.5.1 defective (damaged during construction). D) Service Tests (Gravity Tests) shall be performed on all lines. newly constructed, have been repaired or have otherwise become contaminated, shall be thoroughly disinfected in accordance with GI0151.006, Saudi Aramco Sanitary Code, Chapter SASC-S-01.

Pressure Tests for Plumbing (SATIP-S-040, SATIP-S-060, SATIP-S070, SATIP-S-020) are detailed in procedure as follows: A) Test entire hot or cold water supply system (test & prove tight) under a water pressure of 1034 kPa (150 psig) for 4 hrs minimum. B) Test Gas Systems (welds & j oints accessible) with air, CO2, or nitrogen (Oxygen prohibited) at test pressure not less than 1-½ times SAES-S-060, maximum working pressure, but not less than 60 psi (413kPa) for a Para. period of not less than thirty (30) minutes. D14 C) A low pressure air test not exceeding 345 kPa (50 psig), & soap 103.5.3.3, bubble test shall be used to test sanitary drainage or plumbing system of Para 1204.3.2, any building premises when there is reason to believe that it has become Para. 103.5.5.1 defective (damaged during construction). D) Service Tests (Gravity Tests) shall be performed on all lines. newly constructed, have been repaired or have otherwise become contaminated, shall be thoroughly disinfected in accordance with GI0151.006, COMPANY Sanitary Code, Chapter SASC-S-01. E

E1

Service Test, Leak Test, Minor Repair & Other Applications (Include & detail S ervice Tes t limitations per sc ope) In New Plants, Low pressure steel piping in water, instrument air, plant air, inert gas (Nitrogen, etc.) & steam systems operating at 150 psig or lower are Service Tested (except FW systems).

Vess el Trim & S ampling lines also r eceive a Service tes t.

E2

Service Test After Minor Leak Repairs (in Existing Facilities) is detailed as follows in the procedure (as applicable per scope): A) When small diameter threaded piping (in all services/pressures) repairs are made, thread engagement and seal welding meets S-PMG000-1360-0004 and NDE requirements, followed by Service Test.

S-PM-G0001360-0001, Sec-24.3

S-PM-G0001360-0001, Sec-24.1

S eal weld repairs are not done on Sc h. 40 galvanized joints

E3

Service Test socket welded piping on Tie-in work & repairs (in Existing Facilities) if Operations Engineering Unit determines hydrostatic test is impractical & the following requirements are met: A) A request of NDT in lieu of pressure testing is processed. B) Qualified welders and welding procedures are used. C) Weld gap is verified & welding is witnessed by Operations Insp. D) Welds are MT or PT tested (Operations Inspection choice).

Page 6 of 20

SAES-L-150, Section 9.2

RE-INSP DATE


Rev 3


SAIC NUMBER


ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

E4

Revalidation Tests in Existing F acilities ensure test pressures are the minimum required by ASME B31.3. Actual wall thickness readings (less than 30 days old) and verified flange rating is taken into consideration when calculating the test pressure.

S-PM-G0001360-0001, Sec-23.17

F

F1

Assembled piping is cleaned/flushed per procedure prior to testing: A) Water & Pneumatic flushing (SAES-L-350 App. A) See Att # 2 B) Pressurized Air Shock Blowing (PASB) per SAES-L-350 App. A C) By a Pre-job agreed upon procedure accepted by Company (SA) PMT, Proponent & Inspection representatives.

The general flushing medium is plant/ process water or raw water. Fire water may be used where process water is not available. Sea water is not acceptable. Water for hydrostatic test with pH less than 6 and/or SRB counts greater than 10³ per ml is unacceptable.Treat test fluid to control corrosion and bacteria when applicable.


S-PM-G000114Z-0003, Sec-6.1

E mploy reg ular water analysi s , maintain certs and records.

F3

Test Procedure details Lay-up & treatment of Hydrostatic Test W ater for Carbon & Low Alloy Steel systems as follows: A) Follow 14-day rule with oxygen scavenger & 90-day rule with biocide use in pipelines, use batching scrapers & nitrogen slug to separate air from contacting treated water B) Lay-up per 60-day rule (14 days on exchangers) • Wet, Dry, Inert Gas & Ambient Methods are detailed in procedure • Boiler Layup is per SAEP-1026, Other methods are COMPANY approved.

S-PM-G000114Z-0003 Sec-7.1.1

Pr ocedure can utilize S -PM-G 000-114Z-0003 , S ection 7 in entirety.

F4

Test Procedure details Lay-up & treatment of Hydrostatic Test W ater for Stainless (300, 400 series) systems as follows: A) Chloride content of test water is tested/certified below 50 mg/L. B) Test water pH is 10.0 to 11.0 (add approved soda ash/caustic) C) Treat test water with oxygen scavenger (4-day contact rule) D) Treat test water with biocide (14-day contact rule) and lay-up • Wet, Dry, Inert Gas & Ambient (40% humidity limit) Methods

S-PM-G000114Z-0003 Sec-8.1


F5

Special Test preparation requirements are met as follows: A) Carbon steel atmospheric storage tanks are tested with plant water (untreated) with all traces of water removed after the test. B) Potable water systems must treat the water with chlorine or sodium hypochlorite to effect a residual chlorine concentration between 0.2 mg/L and 0.5 mg/L for disinfection. C) Water is untreated for completely internally coated/lined systems and no lay-up is required for non-metallic systems (e.g., PVC pipe). D) For Dry Gas & Refined Hydrocarbon Product Pipelines, oxygen scavenger is added to test water, use batching scrapers & nitrogen slug to separate contacting treated water (Plant piping exempt) • Lay-up by drying to dew point of -1°C for corrosion control or as specified by proponent within 10 days after test & maintained dry.


Page 7 of 20

S-PM-G000114Z-0003 Sec-9

QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

Cleaning, Flushing, Water Treatment & Lay-up ( Include applicable requirements into the pr ocedure)

S ee Attachment # 2. C leaning and flushing methods are incor porated into the procedure & tes t pack ages . Valve cavity (low point) dr aining , drying , cleaning & rei ns pection measu res s hall be detailed where no low point drains exis t.

F2


N/A

RE-INSP DATE


Rev 3


ITEM No. G

G1

ACCEPTANCE CRITERIA

REFERENCE

Detailed Pressure Testing Procedure Requirements (Include applicable r equirements ) Hydrotest (Pressure Test) Diagrams and procedures include the limits of piping (including test manifold) and equipment included in each hydrostatic test, test pressures, test temperature, test fluid, line flushing requirements, and safety precautions.

Note: P ress ure Test diag rams can cons is t of the following:

Test manifolds are certified & tested to 1.2 times maximum test pressure but not less than discharge pressure of test pump.

G3


• Marked P&IDs & Isometric drawings that use test symbol legend • Copies of Manifold sketches and manifold test certificates. • Procedure can allow multiple circuit testing (show jumper hoses)

G2

SAIC NUMBER

Manifold Tes t Report (S ketch & Certifi cate) is requi red. The s ketch lis ts detailed information/ratings of all components. Manifolds receive unique numbers and records are kept. Procedure details isolation of test sections (checklist items): A) Paddle blinds or spectacle blinds isolate test sections. B) Blind flanges, pipe plugs and caps isolate test sections C) Block valve isolation is severely restricted & supported by calcs.

S-PM-G0001520-0007 Sec-6.5.1

S-PM-G0001520-0007 Sec-6.4.4

SPM-G000-15200007 Sec-8.3

Fabricated tes t implements are rated, marked & ins pected

G4

During the application of the test pressure, all in-line valves if not used as test isolation valves are verified to be in an open position.

Ins pectors check valve lineup & pos ition prior to tes ting.

G5

Block valve use for isolation during hydrotest (testing against the seat of a closed gate, ball or plug valve) is limited & supported with Engineering calculations (limiting factor considerations) as follows: A) Test pressures never exceed seat closure test pressures per API 598 (Example: 150# gate valve seat closure test is at 314 psi) B) Valves do not leakby (Successfully passed a seat closure test) C) Both sides of isolation valve have relief valves during test. D) Test pressure is never reduced below 1.5 x system design pressure per SAES-L-150, Section 7 (ASME B31.3, Para. 345.4.2)

S-PM-G0001520-0007 Sec-8.3.2

S-PM-G0001520-0007 Sec-8.3

E nsure testing ag ainst valve seats caus es no damag e.

G6

Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are reviewed by Engineering & verified by Inspection as follows: • Hoop stress in pipe (nominal wall less mill tolerance) of 90% of Specified Minimum Yield Strength (SMYS) at test temperature. • Flange pressure ratings (1.5xASME B16.5, etc round up 25 value) • Valve pressure rating (1.5xASME B16.34 value, round up 25) • Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design • Internal FBE Coating pressure rating is known, listed & considered

SAES-L-150, Section 7.1 Attachment 2

E nsure limiting factors are lis ted (S IS Sheets/tes t reports) Prevent overpres sur ization & damag e! S ee Excel Sheet 3

G7

Components in new piping systems that interfere with filling, venting, draining or flushing are not installed until after line flushing & pressure testing are complete. (orifice plates, flow nozzles, sight glasses, venturies, metering and other in-line equipment.

Li s t items i n procedure and on reins tatement checklis t

Page 8 of 20

S-PM-G0001520-0007 Sec-8.1.4


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3


ITEM No.

G8

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

Sensitive Equipment excluded from Pressure Test is listed: A) Rotating machinery, such as pumps, turbines and compressors; B) Strainers and filter elements C) Pressure relieving devices (rupture disks & relief valves) D) Installed system gages where test pressure will exceed range E) Equipment that cannot be drained & Instrument Devices. F) Other sensitive equipment designated by SA Inspector* * S oft seated valves & control valves are ins talled AFT E R lines have

S-PM-G0001520-0007 Sec-8.2

been thoroughly flushed (SA E S-A -004 Para 7.1.3) Li s t items i n procedure and on reins tatement checklis t

G9

Vent & Drain installations for testing purposes are as follows: A) Vents are provided at all high points in the piping system. B) Drains are provided at all low points in piping system excluding submarine and buried pipelines. (Dead leg s are not ins talled)

S-PM-G0001520-0007 Sec-8.4

This is a Pre-Hydrotest checklist item verified by Ins pection

G10

G11

G12

Relief valves of adequate capacity are set to relieve at 5% above test pressure. Relief valve(s) are tested, dated, and tagged within one week prior to the hydrotest for new construction projects.

Contractor maintains lis t of relief valves and has a COMPANY approved vendor or sy s tem to do weekly calibrations. I ns pectors witness relief valve calibrations

All joints (threaded, welded & flanged) are exposed for visual leak detection during the strength test. External coating/priming of such joints is not allowed unless approved by COMPANY.

S-PM-G0001520-0007 Sec6.4.1

S-PM-G0001360-0001, Sec-23.16

Test duration and hold times consider full inspection access via scaffolding & manlifts as necessary to allow visual inspection of 100% of S-PM-G000all joints including weep holes, 6mm drain holes in dummy legs 1360-0001, Sec(required). Inspection time may exceed test times listed in SIS sheets & 23.15 Hydrotest reports (30 minute is a mini mum).

Ins pectors s hall complete ins pection before tests are ended. Temporary supports & other support considerations for above ground piping installations during hydrotest are as follows: A) Where required to prevent damage to system G13 B) As highlighted in the approved hydrotesting procedure. C) Expansion joints and spring hangers or spring supports are to be provided with temporary restraints where needed to prevent excessive travel or deformation under test loads.

S-PM-G0001360-0001, Sec25

Filling & pressurization is done upstream of check valves in system. Test fluid enters & drains at lowest points to minimize trapped air. All vents are open during filling. Procedure contains the following: Note: Filling a system too quickly frequently results in air trapped within the system. This accounts for test failures and delay due to noticeable S-PM-G000pressure drops. Test crews shall allow additional time (15 m inutes G14 1520-0007 Secaverage) for air bubbles trapped in test water to vent. After such time & 9.1.1 fluid levels drop at vents, a final slow fill is done.

J us tifi cation for N ote: Thous ands of manhour s are los t due to tes t ailures until s teps are taken to adequately train tes t crews to stop rus hing during filling , ass ure adequate time for proper venting of air & u s e a s low final fill technique.

Page 9 of 20


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Review Pr Procedure - Pressure Te Testing (A (All Ap Applications) PROJECT TITLE

ITEM No.

G15

SAIC NUMBER

SAIC-A-2001 W BS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

Disposal sites for the test fluid shall be reviewed and approved prior to the hydrostatic test in accordance with SAEP-327 "Disposal of Wastewater from Cleaning, Flushing, and Hydrostatic Tests".

Tes t water water reuse is res tricted to ensur e cleanl cleanlines ines s & quality quality

After the test pressure pressure is reached and before before commencement of inspection of the system, the isolation valve between the temporary test manifold/piping and the piping/equipment under pressure test shall be G16 closed & the test pump disconnected. (Use Bold Letters) Note: The isolation valve downstream of the manifold shall then be opened after the pump has been disconnected. Pressure gages & recorder requirements are listed as follows: A) Calibration intervals intervals do not exceed one (1) month. B) Stickers (signed by Inspection) show latest calibration date. C) Gages range for test pressures is 30 to 80% of full range. D) Two gages (accuracy of each within 5%) are used in testing. G17 E) When large systems are tested, additional additional gages are required. required. F) Recording gauges shall be used used where it is necessary necessary to keep a permanent record, e.g.,when the test duration exceeds four hours, or otherwise as required by this standard. A

S-PM-G0001360-0001, Sec25.5

S-PM-G0001520-0007 Sec9.1.2

S-PM-G0001520-0007 Sec-8.1.5

curr ent lis t of gaug es (r ecords ) & cal due dates dates are kept.

G18

If strength test is not practical, it can be substituted with 100% RT & subject to approval by COMPANY

Proces s a reque requess t of NDT in lieu lieu of press ure testing testing .

H

H1

Hydrotesting (Sample Package & reinstatement): (Include/reference reinstatement requirements that apply)

Test procedure details test package contents as follows: • Sample Hydrostatic Test Diagram (see 8.01 above) • Sample Pre-Hydrotest Checklist (sensitive equipment, line flushing) • Sample Relief Valve Data Sheets & Calibration Records • Sample Pressure gage & recorders calibration records • Sample Test Manifold Test Records (1.2 x maximum pressure) • Sample COMPANY COMPANYSafety Safety Instruction Sheet & Pressure Test Report Form • Sample copy of P&IDs used (test boundaries & symbols) • Sample copy of Isometrics used (test boundaries & symbols) • Sample Piping Spools Control Sheet with NDT extent & Result • Sample Inspection & Test Plan Sheet (sign offs) • Sample Re-instatement Check list (Re-instatement is in procedure)

Pr ovide s ample ample test package & proc edure for COMPANY COMPANY approval. approval.

Page 10 of 20

S-PM-G0001360-0001, Sec-23.7

as referenced

S-PM-G0001360-0001, Sec25.1


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Review Pr Procedure - Pressure Te Testing (A (All Ap Applications) PROJECT TITLE

ITEM No.

H2

30-Jun-08

SAIC NUMBER

DATE APPROVED

SAIC-A-2001

22-Jan-14

W BS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

Removal of Test Components and reinstatement of items after pressure testing is addressed in the procedure as follows: A) All temporary items installed for for testing purposes (manifolds, valves, blinds, spacers, gaskets, supports, etc) are removed. B) Components that interfered with system filling/venting/draining & Sensitive Equipment (removed before testing) are reinstalled. C) Items such as instrument air tubing, check valve discs that were disconnected before testing shall be reconnected. D) Isolation valves closed for test purposes required to be i n the open position for process reasons shall be opened. E) If the valve cavity has a drain, the cavity shall be drained. Test procedure details test package contents as follows:

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE

S-PM-G0001520-0007, Sec10

Pr ocedure references and details details the rei ns tatem tatement ent effort

REMARKS: Pressure Test Procedure (S-PM-G000-1520-0007 (S-PM-G000-1520-0007 Definition): Definition): Information Information assembled to ensure all requirements listed in GI-0002.102 , all referenced COPMANY & Industrial standards are met. Per S-PM-G000-1520-0007 S-PM-G000-1520-0007 Definition, Definition, test packages are part of the Pressure Note Test Procedure. This checklist provides a complete detailing of all Pressure Testing Applications/Requirements for COMPANY Projects. See Attachment 1. Hydrotest, Pneumatic and Soap Bubble Leak Test*, Service Test, & Valve Testing, can be one (1) procedure 1 (Pressure Testing). *Note: Testing). *Note: Soap Bubble Leak Test procedure (See SAIC-A-2005) shall meet ASME SEC V Article 10 & Appendix requirements.

Pressure Test Plan is Plan is submitted for Company review & contains the following 4 elements necessary to control the work: 1. Pressure Test Test Procedure Procedure (Including (Including Test Package Controls) Note 2. Sample Hydrotest Package Per SAIC-2003 2 Hydrotest Data Mgmt & Tracking Database per S-PM-G000-1520-0006 4. Pressure Testing Specification (Plant Piping System System Line Class List modified for Pressure test design)

3.

Pressure Testing Specification shows all systems, design factors and proposed system testing details including lay-up and includes all Note Plant Piping Line classes including those for Utilities, Firewater System and Plumbing, to guide pressure test design and test package 3 development. Submit early on major projects as Pressure Testing is almost always Critical Path on Projects. Section A relates to Procedure "Structure" & Sch Q specific Quality Goals such as: 1) Continuing Process Improvement (CPI) & adoption of Note Best Practices 2) Meeting Meeting Company Company Standards Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through through Quality. This 4

s ection i s not repeated repeated in other " R eview P rocedure" roc edure" type s pecial proces s check lis ts, ts , yet is intended for all.

ATTACHMENTS: ATTACHMENTS: Attachment 1 - Pressure Testing Testing Matrix for COMPANY COMPANY Projects Attachment 2 - Pressure Testing Inspection Guide

REFERENCE DOCUMENTS: 1.

Contract Schedule Q - Quality Quality Assurance Assurance and Control, Inspection and Testing (Project Specific) Specific)

2.

Company General Instruction Manual GI-002.102 Pressure Testing Safely Safely

3.

SAEP-1160 Tracking & Reporting of Welding, NDT & Pressure Testing for for Capital Projects

4.

S-PM-G000-1520-0007 General Requirements for Pressure Testing

5.

S-PM-G000-114Z-0003 Hydrostatic Testing Testing Fluids and Lay-Up Lay-Up Procedures

6

S-PM-G000-1360-0001 GENERAL SPECIFICATION SPECIFICATION FOR PIPING

7.

SAES-L-108 Selection of Valves

8.

SAES-L-150 Pressure Testing Testing of Plant Piping Piping and Pipelines

Page 11 of 20


Rev 3 SAIC NUMBER

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Review Pr Procedure - Pressure Te Testing (A (All Ap Applications)

SAIC-A-2001

PROJECT TITLE

ITEM No. 9.


22-Jan-14


ACCEPTANCE CRITERIA

REFERENCE

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE

SAES-L-310 Design of Plant Piping

10.

SAES-L-350 SAES-L-350 Construction of Plant Piping

11.

SAES-S-010 SAES-S-010 Sanitary Sewers

12.

SAES-S-020 SAES-S-020 Industrial Drainage and Sewers

13.

SAES-S-030 SAES-S-030 Storm Water Drainage Systems

14.

SAES-S-040 SAES-S-040 Saudi Aramco Water Systems

15.

SAES-S-050 SAES-S-050 Sprinkler and Standpipe Systems in Buildings

16.

SAES-S-060 SAES-S-060 Saudi Aramco Plumbing Code

17.

SAES-S-070 SAES-S-070 Installation of Utility Piping Systems

Contractor / Third-Party

COMPANY

Construction Representative*

Company PMT

Work is Complete and Ready for Inspection: Name, Initials and Date:

Name, Initials and Date:

Witnessed

QC Re Rec or or d R ev ev ie ie we we d

W or or k V er er ifif ie ie d





Company Inspector

QC Inspector Perfo Perform rmed ed Insp Inspec ectio tion n

Work Work / Rew Rewor ork k May May Pro Proce ceed ed



QC Supervisor

Witnessed

Proponent and Others Quality Record Approved:

Name, Sign and Date:

Name, Organization, Initials and Date:

*Person Responsible for Completion of Quality W ork / Test

Witnessed

Y = YES

Page 12 of 20

N = NO F = FAILED


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Pressure Testing for Plant Piping

SAIC NUMBER

SAIC-A-2001


QR NUMBER

22-Jan-14

MECH-

Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing) SYSTEM Process Piping

ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series) TEST PRESS TEST CONSIDERATIONS & NOTES & DURATION As Calculated* 30 mins (min)

Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength test required per code) with exceptions for Service Test and other tests as noted below. NDE in lieu of pressure test may be performed if requested & approved by SA Insp. Dept. Mgr. Process requests per Sect 5 of SAES-A-004, and at a minimum, 30 days ahead of testing.

*Note: Unless limited by flanges, valves or other component (exceptions below), hydrostatic strength test pressures for every section of new constructed line shall produce a hoop stress in pipe of 90% SMYS at test temperature. See Exceptions Below.

Lube & Seal Oil Systems

See Notes 30 mins (min)

*Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely cleaned* (oil free) before testing. *Baby Powder works best to clean/dry joints

Note: Leaks are common, difficult to identify as "active" or "non-active". Perform preliminary tests to identify all leaks, especially at flanged and threaded joints. When evaluating leakage, utilize clean dry cloths to identify "active" leaks for repair. Oil residue found after wiping the joints (check low points carefully) is cause for clean and retest. Always wait a minimum of 30 mins after wiping joints before reevaluation.

Underground A) Process Piping B) Utility Piping

Flare Lines (24" & above)

As Calculated See Notes

A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B) Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours. If

jus tifi able (s afety, back-fi lled line) a 24 hr recorded test (C hart Recorder) is reqd. See Notes 30 mins (min)

Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3

Note: Test limits shall be downstream of isolation valves (beyond PZVs & locked valves for equipment). Portions of the test may be less than 24 inches from these valves to the flare header branch connection. Flare system Isolation Valves receive a pneumatic seat test at 5 psig in lieu of a high pressure seat hydrotest. Conduct this test on a weekend to minimize personnel exposure. Perform a stored energy calc when requested by Company. Test limits utilize blind flanges at removed isolation valve locations. Follow Pneumatic Testing SATIP.

Vacuum Piping


Air & Inert Gas (150 psig max)

SERVICE TEST & Soap Bubble Test 30 mins (min)

LP Steam (60 psig max)

SERVICE TEST 30 mins (min)

Weld-Plus-Ends (SAIC-A-2016) Existing Plant Piping Incl. Tie-Ins

Soap Bubble Leak Test at 5-10 psig

RETESTING REQMTS

See Notes

As Calculated* 30 mins (min)

Tested to 1.5 times the differential external pressure, but not less than 15 psig. Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded joints are checked for engagement (two full visible thread rule). Coordinate with Compressor and Receiver Service tests and final gasket installation. Coordinate with system Service tests and construction completion. Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus between the gasket and the seal weld. It shall be examined for leaks using a soap solution. For revalidation purposes of existing plant piping, the test pressure shall be minimum required by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be determined and taken into consideration when calculating the test pressure. In case of flanged tie-in connections, a flange tester is utilized to conduct hydrostatic testing of flange butt weld. Systems that already passed a successful pressure test require RETEST IF subjected to new welding activities (Modifications, repair to pressure boundary) OR IF PWHT is reqd*.

Note: Seal welds of threaded connections & Attachment welds of non-pressure containing parts, such as wear pads DO NOT REQUIRE RETEST UNLESS THE LINE REQUIRES PWHT (Including attachment welds & seal welds to the pressure boundary).

REPAIR EXISTING PIPING

See Notes

Every existing plant piping & pipeline, after repairs or alterations have been made that affect the integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test pressure shall be in accordance with the requirements of the applicable code.

Note: SAEP-310 requirements apply as well for pressure testing after Repairs, Upgrades, Refurbishment, etc

Open-Ended Piping

EXEMPT, VISUAL EXAM

Drains, vents & piping downstream of pressure relieving devices that discharge directly to the atmosphere (max internal pressure 10 psig) are EXEMPT from testing. Drain holes installed, etc

Note: Test Package SIS Sheet shows design data & "EXEMPT" under required test pressure. Line(s) shall be visually examined.

Instrument Impulse Lines


Whether piping or tubing, between the root isolation valve and the instrument isolation shall be pneumatically pressure tested (air or nitrogen) at 1.25 X design pressure of the piping system or process equipment to which it is connected. Test duration shall not be less than 30 minutes.

Note: Instrumentation that could be damaged due to the test shall be disconnected. W hen pneumatic test is not practical (pressure greater than 1000 psig, physical configuration, etc.) test with liquid or water. (Flush, test & dry clean using a quality of water not harmful to lines).

Internally FBE Coated Lines


For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not exceed 5,000 psi for APCS 100, 101, 103 systems & 3,000 psi for APCS 102 System

Note: ALL Welding shall be completed (Design Issue), all internal coating and Holiday Testing PRIOR TO pressure testing.

Page 13 of 20


Rev 3


SAIC NUMBER

SAIC-A-2001


QR NUMBER

22-Jan-14

MECH-

Sampling Lines

See Note

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

Vessel & Tank Trim (Piping)

See Note

Test separately (separate package) as required. Exemptions include sight glasses & other instruments. Strength or Service test associated piping based on service

Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test

Skid-Mounted Piping (Vendor)

EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are m ade to skid-mounted piping to correct misalignment, per 01-SAMSS-010 physical damage or any modifications in-situ, pressure test the affected spools. (exceptions noted)

FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042) Test Location Field Testing of New Valves Exception

See Note

See Note

Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure hydrostatic seat test for flare system valves. Identify & Segregate Early!!!

Exemption Procedure

See Note

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

See Note

Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated isolation valves shall have zero leakage. See SAIC-L-2042

(Checklist Item D4)

See Note

Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J All new valves designated for isolation service (as specified by the Proponent) shall be subjected to high pressure hydrostatic seat test prior to installation in line.

Note: Proponent specifies those Line Classes and valves subject to field hydrotesting. Valves received shall be carefully identified & given a unique ID number for installation into the correct Line Class based on visual verification of construction stamp. Valves shall be given a unique ID & corresponding test report document upon receipt, Valve ID shall be controlled, documents transferred into appropriate Test Pkg & Database (Piping System, Line Class, Line Number, Location) per SAEP-1160. Procedure identifies all critical aspects of Valve Testing incl Receipt Inspection (internal visual exam by qualified Inspector), pressure test, ambient lay-up (corrosion protection per mfg instructions & follow-up preservation reqmts) & segregation control to prevent "mixing valves". Controlled System for Valve Placement exists.

SPECIFIC TESTING REQUIREM ENT SUMMARY (ALL SA APPLICATIONS PER SAES-L-150, Section 6) 6.1 Plant Piping - Pressure testing of On-Plot Plant Piping shall be per SAES-L-150. See Section D of this Checklist. 6.2 Cross-Country Pipelines - Pressure testing of cross country pipelines shall be per SAES-L-150. See Section C of this Checklist. 6.3 Pressure Vessels - Hydrostatic testing for new vessels (shop or field fab) shall be conducted as follows: ASME Section VIII, D1 to SAMSS-004, Para 16.3.8.1. & ASME Section VIII, D2 to 32-SAMSS-004, Para 16.3.8.2 Hydrostatic testing for existing vessels shall be conducted per SAES-D-008, Paragraph 10.1. Pneumatic test as approved by Insp Dept Mgr (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2) 6.4 Heat Transfer Equipment - Hydrostatic tests for existing equipment shall be per SAES-D-008. For pneumatic testing, refer to same as above for Vessels (UG-100 of ASME SEC VIII D1, OR T-4 of ASME SEC VIII D2) Boilers receiving Hydrostatic test (new, field fabricated boilers) shall be in accordance with 32-SAMSS-021. Boiler pressure test After Repair or Alteration, refer to SAES-D-008 & National Board Insp Code, NB-23. Boiler Hydrostatic test during T&Is shall be per test pressure as specified on boiler's safety instruction sheet. Heater Tube (coil) Assy Hydrostatic test for new, field fabricated heater tube assembly shall be per 32-SAMSS-029. Heat Exchanger Tube bundles removed from X-chgr (maintenance) get in-situ shell side test per SAES-D-108 prior to return to service Fin Fan X-chgr is strength tested (as stamped) in-situ prior to final acceptance (new project), & whenever transported. 6.5 Tanks - For new, field fabricated tanks, & existing tanks, hydrostatic testing shall be per 32-SAMSS-006 for large, low pressure welded tanks; or 32-SAMSS-005 for atmospheric steel tank, as applicable. 6.6 Fire Protection Systems - Pressure test new & existing fire protection systems (SAES-B-017, GI-1781.001). 6.7 Refrigerant Piping Systems - Refrigerant piping serving building air conditioning systems shall be tested according to the requirements of SAESK-001 and the Uniform Mechanical Code (UMC), Section 1520. 6.8 Potable Water Systems - Potable water piping inside buildings shall be tested per the reqmts of Uniform Plumbing Code (UPC). Exceptions to UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS Potable water piping outside of buildings shall be tested per the requirements of SAES-S-040 (SAES-S-070, Section 18). 6.9 Utility Piping Systems - Utility systems, including irrigation piping & water distribution mains, shall be tested per SAES-S-070, Sect 18 6.10 Industrial Drainage and Sewers - Industrial drainage and sewers shall be tested per SAES-S-020 (SAES-070, Section 18). 6.11 Sanitary Sewers - Sanitary sewer systems within buildings shall be tested per reqmts of the Uniform Plumbing Code (UPC). Exceptions to UPC requirements are listed in SAES-S-060. THERE ARE 3 MAJOR EXCEPTIONS FOR INSPECTION AWARENESS Sanitary sewer lines outside of buildings shall be tested i n accordance with SAES-S-070 Section 18. 6.12 Storm Water Drainage Systems - Test per SAES-S-030 (SAES-S-070, Section 18) Note: Only OWS portions are tested. 6.13 Miscellaneous Building Services Piping - Steam & condensate piping outside the jurisdiction of ASME B31.3, heating & cooling water piping, vacuum & compressed air system piping for building services shall be tested per ASME B31.9, Building Services Piping. 6.14 Gas Cylinders - Gas cylinders shall be tested per Saudi Aramco Bottled Gas Manual. (Application - New Labs, etc) 6.15 Valves - Valves shall be tested in accordance with SAES-L-108, Section 4.7 6.16 Non Metallic Piping - Such as RTR, Thermoplastic, PVC/UPVC & CPVC shall be tested per SAES-S-070, Section 18.

Page 14 of 20



Rev 3 SAIC NUMBER

SAIC-A-2001


22-Jan-14

QR NUMBER

MECH-

Attachment 2 - Saudi Aramco Pressure Testing Inspection Guide For Procedures SAES-L-150 Pressure Testing Definitions Hydrostatic Test: A pressure test conducted using water or other approved liquid as the test medium. Leak Test: A pressure test to ensure tightness of flanged and threaded joints at the test pressure. It is normally conducted before initial start-up & after T&Is. A leak test is different from tightness test below. Pneumatic Test: A pressure test conducted using air or other approved gas as the test medium or in conjunction with liquid. Revalidation Test: A pressure test performed to prove the integrity of existing pipelines or plant piping. Service Test: A pressure test performed to prove the integrity of pipelines or plant piping using the service fluid at the maximum attainable operating pressure. Strength Test: A pressure test at an internal pressure determined in accordance with this standard and the applicable Code* to verify the integrity of the piping systems f or service at the design pressur e. Tightness Test: Pressure test to ensure piping system tightness (i.e., no system leaks) at test pressure. *Strength test (ASME B31.8 code term) is same as a hydrostatic leak test (B31.3) or proof test (B31.4) API 598 & SA Valve Pressure Testing Definitions Shell (Body Hydrostatic) Test: A pressure test conducted using water or other approved liquid as the test medium and applying pressure inside the assembled valve with the valve ends closed, the valve partially open & any packing gland tight enough to maintain test pressure, thus testing the stuffing box. High-Pressure Closure (Hydrostatic Seat) Test: A pressure test conducted using water or approved liquid where pressure is applied successively to each side of the closed valve with the other side open to atm osphere to check for leaks (measured in drops) at the atmospheric side of the closure. Low-Pressure Closure (Pneumatic Seat) Test: A pressure test conducted using air (5 psig unless specified otherwise) where the pressure is applied successively to each side of the closed valve (Flare system valves) with the other side open to atmosphere to check for leaks (measured in bubbles) at the atmospheric side of the closure. SAES-L-350 Appendix A (Cleaning Procedures) Pneumatic flushing with dry air (dew point -1°C or less) or steam with a minimum exit velocity of 15 m/s. Repeat flushing until cleanliness is verified by observing an absence of any solids impact on a polished metal t arget at exit. Pressurized Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an alternative method for initial cleaning of small bore pipe (less than 2 inch). Use PASB if there are problems removing trapped liquid in the piping, or to verif y cleanliness of small bore pipe where video inspection is impossible or inadequate due to pipe dimension or configuration. Air shocking pressure shall never exceed working pressure of the system and shall never be more than 810 kPa (115 psi). Safety precaution shall be considered in consultation with Area Loss Prevention Division when this method is used. Repeat PASB until cleanliness is verified by observing the absence of any solids impact on a polished metal target (mirror) at the exit. Install double filters on air compressors & frequently drain water accumulation to ensure air quality & prevent fouling of piping systems and instrumentation. Water Flushing: Equipment sensitive to damage during water flushing shall be removed, blocked off or isolated. A list shall be prepared and be part of the flushing procedure. Ball valves shall be f lushed in fully open position. All piping systems shall be flushed using high pressure [60.8 mPa (8.8 ksi) minimum] jet such as rotating hose or rotating nozzle. Below 4", use High Velocity Water Flushing (HVWF). On systems where high pressure jet flushing cannot be used due to complicated shapes and/or long runs use HVWF or slug flushing. Water velocity shall be a minimum of 3 m/s. General flushing medium shall be plant/process/raw water. Fire water is used where process water is not available. Sea water is not acceptable. When flushing stainless steel lines, chloride ion content shall be less than 50 mg/L. After flushing, piping systems shall be completely drained, dried to a dew point below -1°C and protected against corr osion. Valve Cavities (low points) without drains shall be addressed in the procedure. Mechanical Scrapers: Can be used under the condition that damage to the pipe interior surface shall not occur. Valve Considerations: Valve Cavities (low points) without drains shall be addressed in the test procedure. Whenever any valve without a low point drain is tested in-line, steps shall be taken to assure: 1) Complete draining of low points including the valve cavity after testing. 2) Complete removal of debris deposited during flushing and filling. Demonstrate effectiveness of flushing to prevent debris accumulation in low points. Reinspection after cleaning and examination of seating surfaces & performance of manufacturer recommended preservation or corrosion control measures is one acceptable method. Contact CSD. 3) Corrosion Protection measures shall be per SAES-A-007. Ambient lay-up of 400* Series (13Cr) trim valves, (Trim 1, 4, 6, 7, 8 & 8A) is prohibited without CSD approved corrosion prevention measures. Page 15 of 20



Rev 3 SAIC NUMBER

SAIC-A-2001


22-Jan-14

QR NUMBER

MECH-

TEST WITH ISOLATION AGAINST VALVE SEATS (CALCS) PER SAES-A-004, SECTION 7.3 Example 1: A typical Carbon Steel Class 150 # system (Proposed for hydrotest at 450 psi, limiting factor = f lange) 1. A test proposes isolatation against a closed valve (gate, ball or plug type). Valve has passed a body & seat test. 2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3 • A 150 # steel gate valve (Ref er to ASME B16.34, Group 1.1 Materials tables & Section 7 Pressure Testing & API 598 Table 3 & Table 4) has working pressure design rating of 285 psi. • Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (285 x 1.5 = 427.5 = 450 psi) • Determine Valve Seat/Closure Test pressure. Design = 110% or 1.1 per API 598 Table 3 (285 x 1.1 = 313.5 psi). • Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 1 minute (valves to 12” NPS) Do not allow a 30 minute hydrotest at 450 psi against the valve seat (because overpressurization results). Resolution: Remove valve from line for test, install a 150# blind flange & proceed with test at 450 psi Or, reduce test pressure to 313 psi & list valve seat closure as ""limiting factor"" if valve cannot* be removed for test (*justification & Example #2 (Spec break between systems): CS Class 150 # system (hydrotest at 450 psi, limiting factor = flange). 1. Test limit is at a 24” Class 300 # Ball Valve (spec break). Proposed test against valve in closed position. Valve passed body/seat test. 2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-004, Section 7.3 • A 300 # steel ball valve (ASME B16.34, Group 1.1 Matls table & API 598 Tables 3 & 4) has working pressure design rating of 740 psi • Determine Valve body hydrotest value. Design x 1.5, round up to next 25 value (740 x 1.5 = 1,110 = 1125 psi) • Determine Valve Seat/Closure Test value. Design x 110% or 1.1 per API 598 Table 3 (740 x 1.1 = 814 psi) • Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 2 minutes (valves 14” NPS & over) Result: Allow 30 minute hydro at 450 psi. Isolation valve is a Higher Class (No seat overpressurization). LIMITING FACTOR CALCS (PREVENT OVERPRESSURIZATION & POTENTIAL DAMAGE) Inspectors: Upon receipt of test packages for new systems, Inspectors always review test packages (SIS Sheets & Test Reports) for errors regarding limiting factor. An organized system of checks takes only minutes per package. • Reduce test pressures for metallurgy such as SS, CuNi, Ductile Iron (flanges, valves) • Reduce test pressures for system limiting factors (flanges, valves, piping of large diameters, internal coatings) Limiting Factors (test pressures on SIS Sheets/Test Report Forms) are reviewed by Engineering & checked for: • Flange pressure ratings (1.5xASME B16.5, etc round up 25 value) • Valve pressure rating (1.5xASME B16.34 value, round up 25) • Hoop stress in pipe (nom. wall less mill tolerance) of 90% of Specified Min. Yield Strength (SMYS) at test temp • Test pressure (B31.3 Par. 345.4.2) is at least 1.5 x system design & considers internal coating maximum allowable service pressure (SAES-H-102 APCS system 100, 101, 103 = 5,000 psi --- APCS 102 = 3,000 psi) Ensure limiting factors are li sted (SIS Sheets/test reports) and are correct per SAES-L-150, Section 7.1 Example #1: A CS 150 # Raw Water System 12LEOU (hydrotest at 450 psi per SIS, limiting factor = f lange) System has Fusion-bonded epoxy (FBE) internally coated piping & valves (check & gate) for corrosive water service. System (ISOs & SIS information match) Design Pressure = 190 psi at Design temperature of 100F. Piping is shown on drawings to be API 5L, Gr B seamless pipe 24” Standard or .375” nominal wall, also 12” Standard or .375” Pipe flanges are ASTM A 105, forged CS, per ASME 16.5. A 150 # gate valve in this service is Ductile iron ASTM A395 epoxy lined body, Bolted Bonnet, ASTM B61/B62 bronze trim. A 150 # check valve in this service is Ductile iron ASTM A395 epoxy lined body, Bolted Cover, ASTM B61/B62 bronze trim. Note: The system test will cover thr ee open gate valves, one check valve (internals removed for test), and one closed gate valve. Quick Calc Steps: 1. Do not accept a test in 150# system against a closed 150# valve (typical for all classes) Do not accept the proposed test against a closed gate valve. Perform thorough review even after finding an error. 2. Determine Flange Pressure ratings as follows: • Pipe flg limiting factor per ASME B16.5 (Table 1-A, Mat'l Group 1.1 = ASTM A 105) Press Temp Rating Table 2-1.1 • Working pressure rating for Class 150 systems @ temp of 100 F = 285 psig (multiply value by 1.5 per Section 8.3) • 285 x 1.5 = 427.5, round up to next increment of 25 = 450 psig (acceptable, as our listed limiting factor is 450 psi) 3. Determine Valve Pressure r atings by checking ASME B16.34 OR API 598 Table 2 & 3 Note: Class 150 Ductile Iron = 400 psig per Table 2 (shell test) & 250 psig (high pressure seat closure test) ACTIONS: Do not accept 450 psig test pressure. Class 150 valves (ductile iron) are tested to 400 psig (250 at seat). B) Request a test pressure reduction to 400 psig and test limit revision & proceed with review, even after 2 errors. 4. Determine piping Pressure ratings as follows in the following code formula based on 90% SMYS (per SA): Use ASME B31.3 code formula t = PD / 2SE & SA requirement Page 16 of 20 of 90% SMYS values for strength test calcs.


Rev 3


SAIC NUMBER

SAIC-A-2001


22-Jan-14

QR NUMBER

MECH-

Formula for pressure is P = t x 2S(0.9)(E) / D S = Stress Values from ASME B31.3 Table A-1 (API 5L Gr. B has a SMYS of 35,000) therefore S = 35,000 t = pipe thickness (nominal less 12.5 % mill tolerance for seamless pipe, less 0.10” for welded plate) Therefore .375” x 87.5%, t = .328” for both 12” & 24” seamless pipe P = unknown & E = Quality Factor from Table A-1A or Table A-1B (Quality factor for API 5L Seamless Pipe is 1.00), therefore E = 1.00 D = outside diameter of piping (all sizes are considered in calcs), therefore 2 calcs will be performed, one for 24” and the other for 12” Calc for 12” pipe ... P=.328 x (2)(35,000)(0.9) / 12 = 1,722.66 or 1,723 psi is rating for limiting factor for 12” pipe Calc for 24” pipe ... P=.328 x (2)(35,000)(0.9) / 24 = 861.33 or 861 psi is rating for limiting factor for 24” pipe Notice how pipe diameter affects pressure! Neither pipe size is near our 400 psi limiting factor 5.Check FBE internal coating spec (APCS 101) indicates pressure rating of 5,000 psi per SAES-H-002, not a factor! ACTION: Review Complete. Return test package to Engineering. Test pressure and arrangement are unacceptable: 1. Test pressure of 450 psig is unacceptable as Ductile Iron Valves are rated for 400 psig. 2. Use of a closed ductile iron valve at test limits is unacceptable.

Page 17 of 20


Rev 3


SAIC NUMBER

SAIC-A-2001


22-Jan-14

QR NUMBER

MECH-

Attachment 3 - Saudi Aramco Pressure Testing Inspection Guide For Procedures OVER PRESSURIZATION ALERT FOR LATERALS

1. 100% HOLD POINT ON LATERAL BRANCH CONNECTION WELDS FOR COMPANY VISUAL EXAMINATION OF ROOT ID. MEANS OF VISUAL EXAM MUST BE PROVIDED (EXTENSION MIRROR / REMOTE VIDEO). USE W INDOW TECHNIQUE FOR ROOT EXAM 2. LATERALS MUST RECEIVE NDE ON ANY EXISTING / SUSPECT ROOT CONDITIONS TO PREVENT POSSIBILITY OF FAILURE DURING PRESSURE TESTING. 3. FULL ENCIRCLEMENT SLEEVES MUST REINFORCE ALL LATERALS. 4. LESSONS LEARNED (HAWIYEH FATALITY) ... NEVER ALLOW LATERALS ON ANY SYSTEM ABOVE CLASS 150# ... CALCS PER ASME B31.3 Appendix H apply. Do not allow overpressurization. See acceptable detail below. Angle may vary.

Page 18 of 20


Rev 3


SAIC NUMBER

SAIC-A-2001


22-Jan-14

QR NUMBER

MECH-

OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)

Page 19 of 20


Rev 3


Page 20 of 20

SAIC NUMBER

SAIC-A-2001


22-Jan-14

QR NUMBER

MECH-

SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Review of Test Package Preparation (Content, Format & Database)

SAIC-A-2003

PROJECT TITLE

WBS / BI / JO NUMBER




REV. NO.



DATE APPROVED

22-Jan-14

SYSTEM ID.




PLANT NO.



MECH-


EQPT CODE


QR NUMBER

MH's SPENT

TRAVEL TIME


NOTES: 1) SAEP-1160 Section 8 details Minimum Test Package Requirements for Projects (Plant Piping, Pipelines, Equipment). Usage of SAEP1160 is mandatory when referenced by Sch Q for contracts with December 2005 cut-off dates and later. 2) Pressure Test Packages are (an integral part of) Test Procedures (See SAES-A-004 definition). Both Contract Sch Q & SAEP-1160 require a Pressure Testing Procedure, along with other procedures & a Test Package for effective/safe pressure testing work control. 3) Submit a single multiple document package as follows (30 days before the start of work per Sch Q) for Company approval: a) Three mandatory Pressure Test Procedures (as applicable) can be combined into one (Hydrotest, Pneumatic Test, Bubble Leak Test). b) Sample Test package with applicable QC records, Forms (per Attachment 1 of the Checklist and as listed below). c) A Re-instatement Procedure and Checklist (Utilize SAIC-A-2006 & SATR-A-2011 or QC forms meeting SATR m inimum content). d) Pressure Test System Matrix (Modified Piping Design Line Index) per checklist as listed below. e) Pressure Test Package Database - Sample Status Report (per checklist as listed below). 4) Sample Test Package System ID & Status Report (Database). This is mandatory on large projects. Procedures shall detail Organizational Control responsibilities for test packages & have provisions for "lost packages" & other system controls for test packages from package design through system completion (MCC) and the QC certification process including turnover of records. 5) Pressure Test Matrix is a modified line list showing all systems and proposed pressure test design for Company approval. Reduce review time significantly & improve efficiency by performing a close review of Pressure Test Matrix & associated system information early on in major projects. "Critical Path" to MCC is nearly always Test Package Completion. Delays are often due to inefficiency, poor organization and planning, a lack of dedicated manpower solely for Pressure Test Package development, coordination, clearance, & inadequate test planning based on a system approach. 6) Test Package Format (Organization of Sections) shall be in the most efficient manner possible to eliminate package size and yet contain all applicable/important test information and documents needed for safe and correct system pressure testing. Copies of any procedures (Pressure Test, Leak Test, Reinstatement) shall only be provided with test packages on review for initial approval by Company. Procedure copies (Pressure Testing, GI-2.102, etc) shall be kept at test sites (test manifolds) with associated Safe W ork Permits. Combining QC forms is encouraged. SATR use is required or alternatively, QC test reports shall contain SATR elements. Increase efficiency & eliminate waste. ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

A

Test Package Database & Format (Minimum Requirements)

A1

Test Package Minimum Content is per Attachment 1 Note: This checklist details SAEP-1160 specific requirements

A2

Pressure Test Matrix (Design) uses a modified system line list and contains specific proposed test information such as system names, line numbers, testing design data (system class, design/test pressures proposed), proposed test medium, test type (Hydrostatic or Pneumatic strength test, Service Test, Bubble Leak Test, flushing requirements, proposed Lay-up, special considerations/treatments, Chemical cleaning, mechanical cleaning, internal FBE coating, and other pressure test design considerations within Remarks section. Submit this Matrix along with a Sample Package

A3

Test Package Data Tracking System (Database) utilizes an elecronic format acceptable to Company and demonstates effective Test package tracking (system/line basis). Database is maintained & kept current & available at all times for Saudi Aramco review.

S ubmit a sample " Databas e Status R eport for T es t Pk g s "

Page 1 of 7

SAEP-1160, Section 8 S-PM-G000-15200006 Sec10

SAEP-1160, Para. 5.1, Para. 5.2

SAEP-1160, Para. 5.1, Para. 5.2

PASS

FAIL

N/A

RE-INSP DATE

A4

Features of the database shall be compatible (linked = preference) with other SAEP-1160 required databases such as Welding & NDT to allow efficient test package clearance control practices on a system or line designation basis. Note: NDT & other special processes (PWHT, PMI, Coatings, etc) frequently hold up test package issuance. To i mprove efficiency, link databases to improve package coordination, prevent rework and retesting, and identify/target outstanding special process work

Page 2 of 7

SAEP-1160, Para. 5.1, Para. 5.2

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review of Test Package Preparation (Content, Format & Database)

SAIC-A-2003

PROJECT TITLE

ITEM No.

A5


ACCEPTANCE CRITERIA

REFERENCE

Individual Test Packages consist of multiple sections: A) Flow Chart per Attachment 2 with an Index Page (Pkg Contents) B) Pre-Pressure Test (Punch List) Section with Checklists & Forms C) QC/NDE/Special Process Documentation (SAEP-1160 Database) D) Pressure Test Section (SIS, system info, test/calibration reports) E) System Cleanliness & Lay-Up & associated documentation F) Re-Instatement Procedure with Final Inspection (QC Certified) Six sections above can be broken down into additional sections as outlined in Pressure Testing Procedure & Sample Test Pkg.

SAEP-1160, Section 8 S-PMG000-1520-0006 Sec10

A6

Test Package Flow Chart (Attachment 2) denotes responsible agencies for tracking & confirmation of various inspection reqmts .Follow methodstatement or procedure approved by company

SAEP-1160, Section 8

A7

Index Page denotes Package Content and has specific signoffs for Quality Control/Assurance. This can be indexed by Section.


B

Pre-Pressure Test Checklist (or Punchlist) Section contains the following:

B1

Pre-Pressure Test Checklist (Punchlist) Section meets the following requirements for specific content and field instruction: A) Specific SAIC-A-2010 - Pre-Pressure Test Checklist (Punchlist) for On-Plot Piping B) SATR-A-2007 - Pre-Pressure Test Check List (QC Form) Checklist shall cover all anticipated workscope items & provide adequate field instruction. Spec Check usage is recommended.


B2

P&ID & Isometric Drawings including a bill of materials/specs. An Index of applicable drawings is included in the test package. Reference all Line List numbers & corresponding dwg numbers


C

QA/QC Documentation Section contains the following (as applicable)

C1

Weld Inspection Summary Sheet (Elements per SATR-W-2008) Note 1: This can be a single Sheet Database including all special process work in strict accordance with S-PM-G000-1520-0006 Note 2: Limited scopes (500 or less welds/project) are exempt and can use a Company approved hard copy tracking system.

SAEP-1160, Section 5.1

C2

Detailed Weld Map (Isos for Plant Piping, pipelines use i sos or sketch with detailed notes and legend as approved by Company)


C3

NDE Records (MT, PT, RT, UT) showing extent, sequence on NDE and selection meeting project specifications


C4

As-Built drawings as applicable to the workscope. Note 1: Test package SHALL show the actual system under test. Ensure piping modifications/revisions/dimensional changes are corrected by hand (red ink is preferable) on isos/sketches. Note 2: Corrections made by hand are acceptable (Initial & date). Note 3: "Provide As-Built drawings" can be listed as a "B" item


C5

Isolation Valve Test Certificates are available & utilize a unique Identification number whenever valves are field tested before their installation into the line for pressure testing.


C6

Flange Joint Assembly Inspection Report (SATR-L-2001).


C7

Internal Cleanliness / Flushing Report (SATR-A-2008)


Page 3 of 7

30-Jun-08 DATE APPROVED QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER


SAIC-A-2003

PROJECT TITLE


ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

C8

Verification of System Readiness for Testing (SAIC-A-2004)


C8

Checklists for test preparation and Test Equipment verification (SAIC-A-2009)


C9

Pressure Test Report Form (SATR-A-2001)


C10

Calibration or Test certificates for the following test instruments as applicable: (Equivalent approved test reports are acceptable) a. Pressure gage and recorders (SATR-A-2002/2004) b. Temperature gage and recorders (SATR-A-2003/2005) c. Test Relief Valve/s (SATR-A-2006) d. Test Manifold (SATR-A-2001) e. Water Analysis (test medium) - (SATR-A-2014)

C11

Reinstatement Procedure QC form & Instructions.

E

System Lay-up

E1

System Lay-Up Certificate Form (SATR-A-2009)

F

F1


22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE

SAEP-1160, Section 8 S-PM-G000-15200007 Para 8.1.5 & 6.4.4



Re-instatement and/or Final Assembly Final Punch List (By the Contractor) a. SAIC-L-2022 & b. SATR-A-2011


REMARKS: REFERENCE DOCUMENTS: 1. SAEP-1160 - Process Controls for Capital Projects. 2. Schedule Q project Specific


Company


Company PMT


T&I Witnessed

Q C R ec or d R ev iewe d

W or k Ve ri fi ed

T&I Witnessed

QC Record Reviewed

W ork Verified

T&I Witnessed

QC Record Reviewed

W ork Verified


QC Inspector

Company Inspector Performed Inspection

Work / Rework May Proceed



QC Supervisor




*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 4 of 7

N = NO F = FAILED


Rev 3


SAIC NUMBER

SAIC-A-2003


QR NUMBER

22-Jan-14

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

Attachment 2 -- NEMA TC 2 (Type EPC-40-PVC) Page 5 of 7

MECH-


Rev 3 SAIC NUMBER


SAIC-A-2003


22-Jan-14

QR NUMBER

MECH-

Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No Test Pack Preparation


Engineering

Contractor QC

(NOTE: Use form SATR-A-2007) Construction

Contractor QC

Construction

Contractor QC

SAPMT

PID

Proponent (By Request)

Construction

Contractor QC

SAPMT

PID

Flushing & Cleanliness

Construction

Contractor QC

SAPMT

PID


Pressure Testing

Construction

Contractor QC

SAPMT

PID

Proponent

System Lay-Up

Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

Clear 'A' Items

S. Aramco Pre-Test Punch Listing

Clear S. Aramco 'A' Items

Reinstate System Final Insp (Contractor)

S. Aramco

Page 6 of 7


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Review of Test Package Preparation (Content, Format & Database) for MCC

SAPMT

SAIC NUMBER

SAIC-A-2003 PID

Proponent

Page 7 of 7


22-Jan-14

QR NUMBER

MECH-

SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Post Test Reinstatement & Checklist PROJECT TITLE





REV. NO.




A1

ACCEPTANCE CRITERIA

REFERENCE

Piping-

SYSTEM ID.

MH's SPENT

proc edure for rei ns tatement. A detailed procedu re to g ive clear ield direction along with a check lis t for this activity s hall be s ubmitted before the s tart of work.

A2

Inspection strategies & plans shall be prepared and agreed on prior to commencing of testing. This is in common with Pipelines. Pipelines simply follow their reinstatement procedure.

SAES-L-350, Para. 17.2 /S-PMG000-1360-0001

A3

Specifically, Procedure shall detail PLAN or STRATEGY to reach "SYSTEM" COMPLETION (Quality Certification) as efficiently as possible while accomplishing critical goals of: A) Effective Water Removal, Disposal & Lay-Up (Post Test) No test fluid shall remain in low spots. Specifically, valve cavities. B) Test Vents and Drains (plugged, seal welded & PT'd) C) Removal & reconnection of components All temporary items installed for testing (e.g., manifolds, valves, blinds, spacers, supports) shall be removed. Valves Installed. Items that were removed from testing shall be reinstalled. Items, such as instrument air tubing, check valve discs reconnected (witnessed). Valve line-up & gasket installations meet specifications.

SAES-L-350, Para. 17.2 & SAES-A-004, Section 9 /S-PMG000-1360-0001 & /S-PM-G0003160-0801

A4

Effective Corrosion Control & Preservation Measures Inspection Coverage and Responsibilities (Package Clearance) Clearly detailed provisions for Retesting after reinstatement Evaluations by Inspection. Construction related provisions.

SAES-L-350, Para. 17.2 /S-PMG000-1360-0001 & /S-PM-G0003160-0801

Page 1 of 11

TRAVEL TIME


PASS

FAIL

General Requirements (Complete SATR-A-2007, listed as Attachment 5 & use SATR-A-2011 & SATR-A-6133) Post Test Reinstatement Procedure & Checklist is required to be developed in accordance with & as part of pressure testing. This is a pressure testing procedure & test package component to be SAEP-1160, developed during package creation as based on workscope & specific Section 8 S-PM"system" requirements. G000-1520-0006 Comment: A s tandard post-test checklis t does not provi de a sec10

PLANT NO.



A

22-Jan-14



QR NUMBER


EQPT CODE


ITEM No.

DATE APPROVED

N/A

RE-INSP DATE


Rev 3


ITEM No. C

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE


22-Jan-14

QR NUMBER

Piping-


PASS

FAIL

N/A

SAIC-A-2010 Checklist (Reinstatement Procedure & Checklist item required (when bold.

SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS (See E-Library, Folder 25)

C1

All joints (flange, threaded, welded or mechanical seals) are left exposed for visual leak detection during the strength test. A) External coating & priming of joints is allowed only if approved by Insp Dept Mgr & proponent Organization Representative. B) The pipe itself can be externally primed & coated to a final coat .

SAES-L-150, Para. 7.3 /S-PMG000-13600001,Sec23.16,System clearance (Controls)

C2

The assembly of bolted flange joints shall be in accordance with SAEP351.

SAES-L-450, Para. 9.4 S-PMG000-1360-0004, Sec-11

C3

Drains shall be provided at all low points of the piping system. Note: Exceptions are submarine & buried* pipelines (*pump-outs)

SAES-L-150, Para. 6.2 /S-PMG000-13600001,Sec-14

C4

Vents and drain valves, both temporary and permanent, conforms with the piping class or rating. ( Refer SAES-L-108)

SAES-L-105, Para. 5.9 /S-PMG000-13600001,Sec-14

C5

Supports are installed. Additional temporary support may be installed as required.

SAES-L-150, Para. 6.3 /S-PMG000-13600001,Sec-25.3

C6

Expansion joints and spring hangers or spring supports are provided with temporary restraints.


C7

Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity, uneven weld profiles, and undercut) shall be removed by grinding and inspected by magnetic particle or liquid penetrant method.

SAES-W-011, Para. 11.6 /S-PMG000-15200011,Para-13.5 & 13.8

C8

Temporary welded attachments to the pipe were ground off and inspected by magnetic particle or liquid penetrant method

SAES-W-011, Para. 11.7 /S-PMG000-15200011,Para-13.6 & 13.8

C9

All threaded joints and faying surfaces shall be seal welded by a continuous fillet weld (required weep holes shall be left unwelded).

SAES-W-011, Para. 11.15.1 / SPM-G000-15200011,Sec-13.14.1

C10

Isolation valves are verified to have been body and seat tested prior to installation through verification of field test certificates.

SAES-L-108, Section 4.7.2 /S-PMG000-1360-0001, Sec-23.11

All in line valves that are not used as test isolation valves are in open C11 position.

Page 2 of 11

SAES-A-004, Para. 9.4 /S-PMG000-15200007,Sec-9.1.3

RE-INSP DATE


Rev 3


ITEM No.

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

During water filling, All vents shall be open during filling and plugged, after water filling and air venting.

SAES-A-004, Para 8.1.1 /S-PMG000-15200007,Sec-9.1.1

C13

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

SAES-A-004, Para. 7.4.2 /S-PMG000-1520-0007 Sec-8.4.2

C14

Disc of check valve is removed, unless check valve has by-pass. Method for storage (plastic bag & tie) allows visual verification.

SAES-A-004, Para. 7.4.3 S-PMG000-1520-0007, Sec-8.4.3

Spare taps of orifice flanges are plugged and seal welded.


C12

C15

All threaded joints up to the first block valve of hydrocarbon pipeline are C16 seal welded. Thread engagement has been verified & accepted.

SAES-L-110, Para. 8.2 /SPM-G000-13600004,Para 17.3

C17

Process instruments and equipment that may be damaged by the strength test pressure are disconnected.

SAES-A-004, Para. 7.2 /S-PMG000-1520-0007 Para 8.1.4

C18

The pressure testing manifold is separately pressure tested to at least 1.2 times the system test pressure but not less than the discharge pressure of the pump used for the pressure testing.

C19

Buried pipeline are adequately bermed or covered to anchor the line during pressure test.

SAES-L-450 Appendix C /S-PMG000-1520-0007

C20

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

SAES-A-004, Para. 7.1.5 (a)/SPM-G000-15200007,Sec-8.1.5

C21

Paddle or spectacle blinds shall be used to isolate test sections. Safety of test "implements" has been checked (SAIC-A-2009)

A bleed valve readily accessible is provided in case immediate C22 depressurization is required.

Page 3 of 11

SAES-A-004, Para. 5.5.4 /S-PMG000-15200007,Sec-6.4.4

SAES-A-004, Para. 7.3.1 /S-PMG000-15200007,Sec-8.3 SAES-A-004, Para. 5.5.2 /S-PMG000-15200007,Sec-6.4.2


22-Jan-14

QR NUMBER

Piping-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER


SAIC-A-2006

ACCEPTANCE CRITERIA

REFERENCE

QR NUMBER

22-Jan-14


ITEM No.

C23


Piping-


PASS

FAIL

N/A

RE-INSP DATE

EVALUATE CLEANING (PROCEDURES) & PROPOSED LAY-UPS: For pipe up to 12-inch NPS - flushed clean of loose scale/debris or scraped prior to commencement of pressure testing per procedure Note 1: If flushing was done with valves in line, cavity cleanliness is highly SAES-A-004, suspect where no low point drains exist. Verify post-test removal of Para. 7.1.2 /S-PMscale/debris/water in low points (Check valve cavities). G000-1520-0007 R andom verification involves Ins pection of valve cavities. Sec-9.2 & 10

This is a standard comment or addition to the punchlis t.

Note 2: Internal Cleaning procedure for pipe size larger than 14 inch shall be submited for review and approval) See SATIP-L-108. Flushing Cert is available in the test package for review All pressure containing components of pipeline, except instruments that C24 may be damaged by the test pressure, were physically verified to be included in test using P&ID, ISOs (Pressure Test Diagram)

SAES-A-004, Para. 5.6.1 /S-PMG000-1520-0007 Para 8.1.4

REMARKS: REFERENCE DOCUMENTS: 1. SAES-A-004, /S-PM-G000-1520-0007, General Requirements for Pressure Testing, (30 March, 2005) 2. SAES-L-105, /S-PM-G000-1360-0004, Piping Material Specifications, (30 March, 2005) 3. SAES-L-108, /S-PM-G000-1360-0001,Selection of Valves, (30 March, 2005) 4. SAES-L-110, Limitations on Pipe Joints and Components, (30 March, 2005) 5. SAES-L-150, /S-PM-G000-1360-0001,Pressure Testing of Plant Piping and Pipelines, (30 September, 2003) 6. SAES-L-350, /S-PM-G000-3160-0801,Construction of Plant Piping, (30 September, 2003) 7. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) 8. SAES-W-011, /S-PM-G000-1520-0011,Welding Requirements for On-Plot Piping, (30 March, 2005) 9. SAEP-1160 , Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects (17 July 2006) 10. SAEP-351, Bolted Flange Joints Assembly (7 Nov 2006)


Company


Company PMT


T&I Witnessed

QC Record Reviewed

Work Verified

T&I W itnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified


QC Inspector





QC Supervisor





Y = YES

Page 4 of 11

N = NO F = FAILED


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Post Test Reinstatement & Checklist

SAIC NUMBER

SAIC-A-2006


QR NUMBER

22-Jan-14

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

Attachment 2 -- NEMA TC 2 (Type EPC-40-PVC) Page 5 of 11

Piping-


Rev 3 SAIC NUMBER


SAIC-A-2006


22-Jan-14

QR NUMBER

Piping-

Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No Test Pack Preparation


Engineering

Contractor QC


Contractor QC

Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

PID


Pressure Testing

Construction

Contractor QC

SAPMT

PID

Proponent

System Lay-Up

Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

SAPMT

PID

Proponent

Clear 'A' Items




S. Aramco Final Insp for MCC

Page 6 of 11


Rev 3


SAIC NUMBER

SAIC-A-2006


QR NUMBER

22-Jan-14

Piping-

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








Underground Process Piping Flare Lines (24" & above)


A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum of 2 hrs B) If justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd.




Vacuum Piping




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

SERVICE TEST 30 mins (min) Soap Bubble Leak Test at 5-10 psig

Existing Plant Piping Incl. Tie-Ins


RETESTING REQMTS

See Notes




See Notes



Open-Ended Piping

EXEMPT, VISUAL EXAM











Page 7 of 11


Rev 3


SAIC NUMBER

SAIC-A-2006


QR NUMBER

22-Jan-14

Piping-

Sampling Lines

See Note



See Note



Skid-Mounted EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are m ade to skid-mounted piping to correct misalignment, per 01-SAMSS-010 Piping (Vendor) (exceptions noted)

physical damage or any modifications in-situ, pressure test the affected spools.


See Note

See Note


Exemption Procedure

See Note


See Note


(Checklist Item D4)

See Note




Page 8 of 11



Rev 3 SAIC NUMBER


SAIC-A-2006

QR NUMBER

22-Jan-14

Piping-

Attachment 4 - SPEC CHECK INSTRUCTIONS 1) Test Package Review Tool & Special Process Clearance Verification BEFORE Hydrotest. a. Use Spec-Check along with SAIC-A-2003 (Checklist for Hydrotest Package Review) & this checklist. b. Check test package Bill of materials against piping line class requirements (See sample Spec Check) c. Check NDT requirements in SPEC-CHECK against NDT enclosed in given test packages. Check for correct NDT extent specified and correct NDT methods. Check NDT reports and compare RT field markings to the test reports. d. Check RT reports closely for repairs (repair shots, penalties) & field verify the markings exist on the correct joint. Note: If discrepancies exist, simply review the film and follow NDT checklists for RT (Clear direction exists here). e. Shop/Field Weld NDT requirements vary and need to closely checked for omission of work. (10% shop, 100% fld) f. Check PWHT reports against material spec requirements (service, thickness, etc). Verify visually PWHT was done g. Check BHT reports against spec requirements (sweet & sour services). Verify roundness of Brinnell indentation. h. PMI OK markings exist on those joints PMI examined. Verify markings to correct joint. i. Check color codings of materials to assure correctly specified material was used in piping systems. 2) Check field installations (Pre-Hydro Walkdown, Surveillances) for following special processes: a. Gasket Installation – HOLD POINT FOR CONTRACTOR - Visual before installation, Color code Table CRITICAL: COLOR CODES EXIST FOR ALL GASKETS (TABLE COVERS ALL GASKETS IN ALL LINE CLASSES) b. Bolting Installation & Torque (Bolts, Nuts, Lubricants, Friction Factors, See Torque Tables) c. Valve Installations (Check Valves installed against SAES-L-105 Spec T able Attached) d. Piping specs and piping schedules cab be included e. Check Spectacle plates, blinds, spacers, Jack screws, etc for SPECIFIC SASD DRAWING conformance. f. Check miscellaneous material elements (Class & pressure ratings for weld bosses, fittings) & Limitations (L-110) g. Check W PS and any special instructions needed per welding (invaluable tool for Control) 3) Perform FOCUSED ASSESSMENTS with both CHECKLISTS & SPEC-CHECK 4) Perform Focused Assessments with Spec-Check alone on all specified Materials 5) Perform Focused Assessments with Spec-Check alone on Special Construction Processes. 6) Perform Post-Hydro Checks “in the field” (Reinstatement, FEIL, Pre-Commissioning, Commissioning) a. During Reinstatement, Use Spec-Check along with SAIC-A-2010 (Checklist for Hydrotest Reinstatement) to ensure correct installation (Bolting, valves, etc) b. During FEIL walkdowns, use Spec-Check during accumulation of Field Exception Items List (FEIL) c. During Final walkdowns, use Spec-Check one last time (Pre-Commissioning, Commissioning) 7) Add notes for: WPS Review/Compilation after Review of Line Class Tables, Valve Spec codes, flanges, special walk down notes, supports, etc by using a numerical code and hand written notes on back! SPEC-CHECK can be modified for any item. Ensure the best quality on your project! Check all specs

Test Package Review Notes 1. Check status sheet for signoffs. 2. Check Index against contents 3. Pressure Test Data Sheet • Check drawing numbers against actual enclosed • Check excluded equipment & especially if there are any P&ID notes • Check pressure test value proposed to assure limiting factor is correct (usually a flange) 4. Do a Weld Tracker NDT report review (detailed) • Compare completed Special Process reports (RT, MT, PT, PWHT, BHT, PMI, etc) • Compare against list of outstanding NDT (Backlog of Penalty & Repairs) 5. Review P&IDs and isometrics against spec check for line class required materials (drawings often are in error) Note: Make note on cover in Punch list Accepted by PID “Field verify against Spec/B.O.M” This is especially critical for Sour Service & Special Service lines. Note: Ensure orifice flange reports are included & any NDT specified 6. Check hydrotest diagram • Manifold arrangement sketches must show all elements, & manifold construction/insp must be per SAIC-A-2009 Caution: Ensure test pressures do not exceed manifold element ratings (Valves are next size up for systems tested) Example 1: Class 300 # systems(1125 psi) would utilize a Class 600 Isolation valves in test manifolds at minimum. Example 2: A manifold with 800# gate valves will not be used in testing 600# systems (2250 psig) Reason: You are testing against the valve seat (closed position) & this is rated for 1.1 times test pressure, not 1.5. See Next Page for Spec Awareness (Basis for Spec Check on Projects) Page 9 of 11


Rev 3


SAIC NUMBER

SAIC-A-2006


22-Jan-14

QR NUMBER

Piping-

SPEC AWARENESS PID’s ATTENTION TO SPECS & SPEC-Check (Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects: Initial Review of SPECS 1. Carefully recheck Contractor Piping Specs (Line Class Summary & Tables) as early as possible during or just after Design is complete (as soon as they are issued and available). 2. This is done by checking Contractor’s specs against Line Class Material requirements listed in SAES-L-105. Give special attention to critical systems & systems above 300#. 3. Average large projects can have as many as 50 different piping specs & details can be very hard to pick up in the field. Pipelines have fewer specs and are easier to manage. THIS INCLUDES THE MAZE OF GASKETS!!! 4. Time taken for early review only takes an experienced plant inspector 2 days of review. Findings (often human error) can be critical. Help prevent unplanned shutdowns on your projects & find substandard m aterial specs before they are installed or before they enter service. 5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon as they are issued and available). 6. This is done by checking Contractor’s Special Process Specs against code and SA requirements (SAES-W-011, Sect 17 for NDT & 13 for PWHT). SAES-W-012 is similar to SAES-W-011 in this respect 7. Ensure that notes are included in these SPECS that require increased NDT based on “field welding” and other code considerations. 8. Clear violations such as our “weekly highlight example” (such as specs and drawings that use 3000# fittings on a 900# system instead of required 6000# fitt ings) must be item ized & brought to SAPMT attention early. See attached Sample Weekly Highlight. 9. After all SPECS submitted by Contractor are accepted ... “CREATE” your custom SPEC-CHECK (sample attached with instructions). Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task for self-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* and substandard installation identification*. *FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWARE OF MANY CRITICAL REQUIREMENTS! SPEC CHECK PUTS THESE DOWN ON PAPER (BY SYSTEM)

Test Package Review & Pre-Hydro Walkdow 1. Follow-up (after initial specification review/approval) can also include checking ISO drawings and bill of materials against approved specs before Pre-Hydro Walkdown 2. USE YOUR CUSTOM “SPEC-CHECK” on every new plant project as the perf ect walk down and test package review tool. Important Note: Never assume drawings or test packages are correct. Never assume NDE % & PWHT, PMI, etc performed/not performed by contractor is correct. Inspectors must be taught a systematic review method for test packs with focus on Specs. A thorough test package review system is a page by page review that takes only 15 minutes per package & checks every page and every weld & all materials for com pleteness/correctness. Omission of Special Process work by Contractor is widespread & frequent, most often unintentional and simply due to a lack of AWARENESS.

Surveillance & Focused Assessment 1. Use SPEC-CHECK on routine surveillance. 2. Create a custom SPEC-CHECK for focused assessments on Valves. Incorrect valve installation is very common with valves placed in the wrong service (swapped, mislocated, mismark) 3. Create a custom SPEC-CHECK for focused assessments on small diameter piping (UT purposes). Past projects have seen as many as 20% of all piping segments installed of the wrong schedule of piping (J-80, RT Refinery). I visit projects and find numerous substandard installations very often (human error, again). On your project, order/request/perform/get Contractor to do random checks of small diameter piping segments (2” & below). I do it myself with a 2-man crew with me, piping schedules in hand on all my projects & run at about a 2% reject rate. 4. Create a custom SPEC-CHECK for focused assessments on PWHT & BHT. Past projects have seen poor practice with failure to follow 12-step BHT procedure per NACE RP-0472 App A. 5. Turn your project surveillance into an effective and efficient Inspection asset that is valuable to Projects.

SHARE SPEC CHECK WITH YOUR CONTRACTOR FOR QUALITY Page 10 of 11

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SATR NUMBER

SAUDI ARAMCO TEST REPORT Pre-Pressure Test Checklist (Form)

31-Dec-05 DAT E APPROVED QR NUMBER

SATR-A-2007

PROJECT TITLE

22-Jan-14


MECH-




TEST SYSTEM No./Test Pack No.

PLANT NO.

DRAWING NUMBER (P&ID/ISO) / REV. No.

PRESSURE TEST DIAGRAM

NATURE OF TEST

WORK PERMIT REQD?

SUPPORTING SAIC Number

SAIC QR No.

SAUDI ARAMCO TIP (SATIP) NUMBER

SATIP Activity No.

ATTACHMENT 5 (Guide for Post-Test Reinstatement Checklist by Contractor) Notes: 1) This Form shall be used in conjunction with applicable Pre-Pressure Test Checklist. Refer to applicable SATIPs & See Attachment 1 2) "A" items are items required to be completed before pressure test can proceed. 3) "B" items are post-test items to be cleared immediately after pressure test (within 24 hours) with Inspection witness per procedure. 4) "B" items are completed during re-instatement per an approved Procedure before final inspection by Company (per procedure). Note: "B" items not complete during re-instatement (by approved procedure) shall be transferred to "zFEIL Form 6133" (Attachment 2) 5) See SATR-A-2011 for Re-instatement Checklist Form. 6) ETC = Expected Time of Completion or Expected Start-up Date if ETC date is unknown (affects lay-up considerations) I T E M

Pre-Pressure Test Checklist Items & Description

Reference

B

Originator

ETC (Note 6)

Verified complete by QC

Concur PID Insp

A

or

1

Seal weld threaded nipples from headers to root val ves at (5) locations (hydrocarbon service) per SAES-L-109, Section 8.


A

ABC/QC

1/1/2007

DEF-1/1/07

RLC 1/1/07

2

Guides are in direct contact with piping horizontal run at 3 locations (6mm gap req'd). Relocate guides per drawing. These are welded to the pressure boundary.


A

ABC/QC

1/1/2007

DEF-1/1/07

RLC 1/1/07

3

Check valve upstream clearance is not five (5) pipe diameters (40" req'd, 20" actual), in violation of SAES-L-108.


A

ABC/QC

1/1/2007

DEF-1/1/07

RLC 1/1/07

4

Check valve is oriented in the wrong direction (flow arrow). Reverse check valve to assure correct flow direction. Reposition valve & restore internals immediately after test, COMPANY to witness.


B

ABC/QC

1/4/2007

DEF-1/4/07

RLC 1/4/07

5

Piping clearance to structural braci ng is 15 mm in violation of SAES-L-310, Sect 12. (50 mm spacing req'd). Engineering!


A

ABC/QC

1/1/2007

DEF-1/1/07

RLC 1/1/07

6

Install permanent gaskets at flange set s 1, 4, 5, 6 on ISO dwgs per approved torque tables and install spectacle blinds oriented as per approved P&ID.

SAEP-351, Proj Dwgs

B

ABC/QC

Start-up date = 5/1/2007

7

Completely remove all water and debris from low point/valve cavity for the (3) in-line Valves (8" - 300 #) with SS 400 trim, do so immediately after test. Clean with dry compressed air and relubricate sealing surfaces with approved lubricant in preparation for "ambient" lay-up specified in test package. NOTES: a. Above Items are samples for form use. b. Indicate " No Punch items. " as applicable c. QA col is reviewed/initialed/dated prior to package certification to verify completeness

SAES-A-007, Para 6.2

B

ABC/QC

1/4/2007

DEF-1/4/07

RLC 1/4/07

Reference & Applicable SATIP

A or B

Originator

ETC (Note 6)

Verified complete by QC

Concur PID Insp

8

I T E M

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Reinstatement (Post-Test) Checklist Items & Description (Option per Note 5 Above)

Reinstatement Procedure ditto

Flushing & hydrotest complete and documented as accepted. All test vents & drains plugged and seal welded Lines drained and lay-up per customer approved specificati on

ditto

Valves (400 SS Trim) tested in-line removed, cleaned, & lubricated for Amb lay-up

ditto

Jacking screws, process blinds (spectacles, spades, etc) correctly installed

ditto

Spring Hangers & components (bellows, etc) adjusted per mfg instructions.

ditto

Weepholes plugged with heavy grease (rei nforcement pad air test complete)

ditto

Chain wheel operators installed

ditto

All instruments, control valves & check valves reinstalled in correct flow positi on

ditto

Restriction orifice/flow elements installed

ditto

Relief Valves are Pop tested/calibrated, tagged and SAP approved/installed

ditto

All Temporary Test Components (spools, test blinds, gaskets etc) are removed

ditto

Correct bolts/gaskets are install ed and torqued per SAEP-351 requirements

ditto

Check Valves and internals reinstalled (Internal Cleanliness & gasket check)

ditto

All Start-up items installed (strainers, filters, other it ems restricted from test)

ditto

Chemical Cleaning completed and documented Final Line Check complete & meets all special process specs. See Spec Check. NOTES: a. Above Items are samples for form use only. b. Re-instatement Procedure shall detail specific items to be used in this ReInstatement checklist (per SAEP-1160, Sect. 8). The above 17 items are a sample of such a procedure checklist. c) Indicate " No Post Test items. " as applicable d). QA col is reviewed/initialed/dated prior to package certification to verify completeness

Page 11 of 11

Q A

Q A


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Lay-up of Piping Systems or Vessels PROJECT TITLE

SAIC NUMBER





REV. NO.



22-Jan-14


ACCEPTANCE CRITERIA

REFERENCE

A

General Requirements

A1

Lay-Up Procedure or Method Statement shall be project specific and identified in Project Quality Plan. (SPECIAL CONSTR. PROCESS).

Note Si g nificant chang es to SA E S-A -007 (Oct 2005 Revis ion)

PLANT NO.



MECH-

SYSTEM ID.



QR NUMBER


EQPT CODE


ITEM No.


MH's SPENT

TRAVEL TIME


PASS

FAIL

N/A

RE-INSP DATE

Sch Q, Para. 3.1

A2

SAES-A-007, As SAES-A-007 is intended to be a procedure guide, the Contractor shall Section 1 cut and paste as much of the document as applicable into any (Scope) S-PM-G000procedures to be submmited to Company for review/approval. 114Z-0003 Sec-1

A3

Procedure covers SAES-A-007 General Reqmts regarding: A) Water Quality B) Planning & System Design for Lay Up See Attachment 1

B

CARBON STEEL & LOW ALLOY (P-No. 3/4/5) PRESSURE PIPING SYSTEM LAY-UP (See Section C for Specific Applications)

B1

Procedure details Treatment of Hydrostatic Test Water: When the CS equipment contact time with hydrotest water may exceed 14 days (14-day rule), approved oxygen scavenger (App. 1) shall be added to the hydrostatic test water. Treat water before it enters the system. Use batching scrapers and/or a slug of nitrogen to separate the air in the system from coming in contact with treated water, then fill systems with water injecting sufficient oxygen scavenger to maintain its residual concentration at greater than 20 ppm & an oxygen concentration of less than 10 ppb.

B2

Procedure meets/addresses/details the following requirements: A) Equipment must be laid-up after hydrotesting unless it can be ensured that it will be returned to service within 30 days from the first introduction of hydrotest water to the system. B) SAES-A-007, One of the lay-up methods in Item B3 shall then be selected. Para. 5.2.1 / S-PMC) Section C of this checklist (Specific system & equipment reqmts) G000-114Z-0003 D) Lay-up procedures for pipelines under the responsibility of Para-7.2 & 6.6 Pipelines Dept shall be approved prior to hydrotest by the General Supervisor, Pipelines Technical Services Division (PTSD), & by the Mgr of the concerned area. Approval of lay-up procedure for other equipment shall be the responsibility of Company Eng Suptd. or designate.

B3

Procedure identifies different lay-up methods selected: A) Wet Lay-up (Attachment 2) B) Dry Lay-up (Attachment 3) C) Inert Gas Lay-up (Attachment 4) D) Ambient Lay-up (Attachment 4) E) Other Approved Lay-up Methods (Attachment 4)

SAES-A-007, Para. 5.2.1 / S-PMG000-114Z-0003 Para-7.2

B4

Procedure states step by step for implementation of Lay-up method: A) Verify the appropriate steps cover specific lay-up procedure in attachments 2, 3, & 4 and refer to SAIC-A-2018 (Application). B) SAIC-A-2018 & SATR-A-2009 may be used as a supplementary Layup Procedure.

SAES-A-007, Sec. 5.2.1 / S-PMG000-114Z-0003 Sec-7.2

Page 1 of 12

SAES-A-007, Section 4 /S-PMG000-114Z-0003 Sec-6

SAES-A-007, Para. 5.1 / S-PMG000-114Z-0003 Sec-7.1.1

B5

At end of lay-up, commission & start up heat exchangers shall be within 14 days, & other equipment within 60 days. This statement is included in Procedure for Carbon Steel Equip.

Page 2 of 12

SAES-A-007, Para. 5.3 / S-PMG000-114Z-0003 Sec-7.3


Rev 3


ITEM No.

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

C

SPECIFIC & SPECIAL LAY-UP REQUIREMENTS (Specific Applications)

C1

Tank requirements are listed in applicable p rocedures: Carbon steel SAES-A-007, open-roof, floating-roof, or API atmospheric cone roof tanks not designed for service above atmospheric pressure, Para 7.1 / S-PMG000-114Zdo not require treatment of of hydrostatic water. Immediately after 0003 Sec-9.1 completion of the hydrostatic test, drain and remove all traces of visible water. Cleaning shall consider any coating operations.

C2

Utility System requirements are listed in applicable procedures: A) Utility and potable water systems shall be tested in accordance with SAES-S-060 or SAES-S-070, as appropriate. B) Potable water systems shall be tested with fresh potable water only following the requirements of SAES-S-070, Para 18.2. Oxygen SAES-A-007, scavengers and biocides shall not be used i n potable systems. Para 7.2 / S-PMC) For potable water systems, use Dry lay-up per Para. 5.2.3, Inert gas G000-114Zlay-up using nitrogen per Para. 5.2.4, or Ambient lay-up per Para. 5.2.5. 0003 Sec-9.2 See Attachments 3 & 4. D) For Dry-up (moisture removal), sweet gas shall not be used. Methanol or other dehydrating chemicals shall not be used. Procedure details dry-up methods used & means of verification


22-Jan-14

QR NUMBER

M ECH-


PASS

FAIL

N/A

RE-INSP DATE

Dry Gas & Refined Hydrocarbon Product Pipelines & Piping. See Attachment 5.

SAES-A-007, Section 7.3 / SPM-G000-114Z0003 Sec-9.3

C4

Sour Gas & Sour Oil Pipelines. See Attachment 5.

SAES-A-007, Section 7.4 /SPM-G000-114Z0003

C5

PLANT SYSTEMS (PIPING & EQUIPMENT) SHALL BE LAYED UP PER ATTACHMENT 6. Inspectors are familiar with these reqmts.

SAES-A-007, Section 7.4 /SPM-G000-114Z0003 Sec-9

D

STAINLESS STEEL PRESSURE PIPING SYSTEM & EQUIPMENT (P-No. 6 & above) LAY-UP (INCLUDING NEW VALVE REQMTS)

D1

Type 300-series stainless steel systems* shall be tested only with water having maximum allowable chloride concentration of 50 ppm. Quality of water shall be per Attachment 1. Para. 4.2 in entirety.

C3

CS sys tem with 300 Series S S trim valve is not a SS " sys tem". WATER QUALITY IS TES TED & CE RTIFIE D (SATR-A-2014)

D2

SAES-A-007, Para. 6.1 S-PMG000-114Z0003 Sec-8

Type-400-series stainless steels are highly prone to atmospheric corrosion. This includes valves with trim designated 13Cr*. *Note: Trims # 1, 4, 6, 7, 8, and 8A are affected by new rule. SAES-A-007, Corrosion Controls shall be implemented in procedures as follows: Para. 6.2 & S A) Type 400-series stainless steel trimmed valves shall be removed from PM-G000-114Zpipelines before hydrotest. (In-line spools are used for testing) 0003 Sec-8.4 B) Option B: If it impossible to remove such valves from the line, then SAES-L-105 / Valve Trim written hydrotest procedures must be prepared and approved ahead of Table time allowing the valves to remain in place. See Attachment 7 (Special Notes for 13Cr Trim Valves) Quality Managers & Inspectors are aware of the new reqmt

Page 3 of 12


Rev 3 SAIC NUMBER



SAIC-A-2007

22-Jan-14


ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

D3

When equipment containing any Type-400 series stainless steels is left in place (Option B above), it shall be hydrotested per reqmts of Paragraph 6.3, 6.4, and 6.5 of SAES-A-007. See Attachment 7.

SAES-A-007, Para. 6.2 & SPM-G000-114Z0003 Sec-8

D4

Hydrotest procedure shall carefully detail measures to prevent corrosion including lay-up of the equipment. See Attachment 7. Do not use ambient lay-up for equipment of 400-series SS.

SAES-A-007, Para. 6.2 SPM-G000-114Z0003 Sec-8

QR NUMBER

M ECH-


PASS

FAIL

N/A

RE-INSP DATE

REMARKS: NOTES: 1. Utilize SAIC-A-2018 and SATR-A-2014 in conjunction with this checklist. 2. Quality Managers shall ensure Procedures address the new revisions of SAES-A-007 & Valve Lay-up Considerations. ATTACHMENTS: Attachment 1 - SAES-A-007, S-PM-G000-114Z-0003 Hydrostatic Testing Fluid and Lay-Up Procedure. Attachment 2 - LAY-UP FOR CARBON STEEL SYSTEMS (WET METHOD) Attachment 3 - LAY-UP FOR CARBON STEEL SYSTEMS (DRY METHOD) Attachment 4 - LAY-UP FOR CARBON STEEL SYSTEMS (INERT GAS, AMBIENT & OTHER METHODS) Attachment 5 - SPECIAL LAY UP PROCEDURES (Dry Gas & Refined Hydrocarbon Product Pipelines & Piping, Sour Gas & Sour Oil Pipelines) Attachment 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT)

REFERENCE DOCUMENTS: 1.

SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (3 July 2007)


Company


Company PMT


T&I Witnessed

QC Re co rd Re vi ewe d

W or k Ve ri fi ed

T&I Wi tnessed

QC Record Reviewed

W ork Veri fi ed

T&I Wi tnessed

QC Record Reviewed

W ork Veri fi ed


QC Inspector





QC Supervisor





Y = YES

Page 4 of 12

N = NO F = FAILED


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Lay-up of Piping Systems or Vessels

SAIC NUMBER

SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

Attachment 1 - SAES-A-007 (Oct 2005 Rev) GENERAL SYSTEM REQMTS Responsibility 4.1 In the case of new construction, the construction agency shall be responsible for adhering to this specification; Projects Inspection shall be the monitoring authority. For existing facilities, the facility proponent Maintenance and Operations shall be responsible for adhering to this specification; the proponent's Operations Inspection organization is the monitoring authority.

4.2 Water Quality 4.2.1 Water quality of intended hydrostatic test waters shall be determined well ahead of actual testing dates so that alternative water sources may be identified if original source water fails to meet reqmts. 4.2.2 Water quality of hydrostatic test waters shall be reconfirmed by testing as close to the time of the hydrostatic test as practicable. In cases where individual tanker trucks are used to supply a test, the water samples shall be drawn from a representative number of actual truck loads being delivered to test sites. 4.2.3 Water used for any part of the hydrotesting or subsequent lay-up shall have a sulfate reducing bacteria (SRB) count of 103 per ml or less as determined by the RapidChek II Method or alternative test method approved by Supervisor, CTU/ME&CCD/CSD. Water that has a higher bacteria count may be accepted at the discretion of the Supervisor, CTU/ME&CCD/CSD, after treatment with biocide & retesting. 4.2.4 If water from more than one source will be used, ensure that mixing waters will not cause scaling. 4.2.5 Water used for any part of the hydrotesting or subsequent lay-up shall be clean and free from suspended matter. Suspended matter in the water shall be extracted, before use, by a filter capable of removing 99% of all particles 53µm (2.1 mil) in diameter and larger, or equivalent to using 270 mesh wire mesh screen. 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 Prev Dept, Dhahran. Exception: Paragraph 5.2.2.1 describes controlled circum stances where water treated with a biocide m ay be used for the hydrotest itself. 4.2.7 Water may be reused for hydrotesting, as in a pipeline tested segment by segment. The water must meet the requirements of Paragraph 4.2.3 and must have an oxygen level of less than 20 ppb, or additional chemical treatment will be required. SS Piping (Exception to 50 ppm Chloride rule): In special cases, with prior written approval of CSD, water of up to 250 mg/liter chloride ion is permitted, provided: a) that hydrostatic test period is less than 4 days & b) system is rinsed with steam condensate or demin water until the effluent chloride content reaches below 50 mg/liter, and (c) that the system is completely drained immediately after hydrostatic test and rinse. (SAES-A-007, Para. 6.1)

Lay Up Planning & Design 4.3 Minimize the time between introducing hydrostatic test water and commissioning the equipment. 4.3.1 Schedule the hydrostatic test as close as possible to the start-up date. 4.3.2 Where there are limitations in this standard on contact time for hydrotest water, this shall be from first introduction of water into system until commissioning or until implementation of a complete lay-up. Partial or complete refilling of the system shall count as continuous, cumulative time. Time limitations requiring the initiation of a formal lay-up program shall be from the first introduction of hydrotest water. 4.4 Design the hydrostatic test and the lay-up procedure to protect the most corrosion-susceptible material in the system. THE END

Page 5 of 12


Rev 3


SAIC NUMBER

SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

Attachment 2 - LAY-UP FOR CARBON STEEL SYSTEMS Wet La -u See Attachment 8, Ox en Scaven er A endix 5.2.2.1 Wet lay-up shall be achieved whenever possible by displacing the hydrotest water from the line after hydrotest and replacing with appropriately treated lay-up water. This minimizes the personnel safety and environmental risks of hydrotest ruptures releasing biocide-treated waters. In cases where this is not possible, wet lay-up will require the use of water adequately treated with oxygen scavenger and biocide at the beginning of the hydrotest and will require safety and environmental reviews of the procedure. 5.2.2.2 For wet lay-up, establish and maintain throughout the system a minimum residual oxygen scavenger concentration of 20 ppm in the water and a maximum oxygen concentration of 10 ppb. This includes dead legs. Analyze water sample(s) for residual levels of oxygen scavenger and the dissolved oxygen concentration at the location most remote from the oxygen scavenger inlet. Record the test results in the hydrostatic test report. Once minimum residuals are verified, keep systems tightly closed to prevent air entry. Repeat tests and ensure chemical residuals every six months during lay-up unless the physical location of the line or equipment makes this impossible. If a leak occurs or air enters the system, lay-up the system again after completing repairs. 5.2.2.3 Maintain the system under a positive pressure between 210 to 350 kPa (30 to 50 psig) using nitrogen, a sweet hydrocarbon gas, or hydraulic pressure of the treated water. In cases where the design pressure is lower than 350 kPa (50 psig), the pressures shall be adjusted accordingly. Install thermal relief for systems that are to be laid up with hydraulic pressure. 5.2.2.4 Use gauges with a scale range not exceeding three times the target pressure to monitor the positive pressure in the system during lay-up. The gauges must be capable of withstanding the design maximum allowable operating pressure (MAOP) of the system to which they are connected or must be protected with adequate gauge saver devices if they are not capable of withstanding system MAOP. 5.2.2.5 When the total equipment contact time with water may exceed 30 days, microbiological growth shall be controlled by one of the following methods. 5.2.2.5.1 Use a proprietary combined biocide, corrosion inhibit or & oxygen scavenger at a concentration in the range of 350 – 500 ppm. The disposal plan for this treatment must be approved following SAEP-327. When using a combined product that contains oxygen scavenger, the oxygen scavenger component of the product will be considered sufficient to meet the requirements for oxygen control. 5.2.2.5.2 Use a combined biocide and corrosion inhibitor at a concentration in the range of 150 – 200 ppm. The disposal plan for this treatment must be approved following SAEP-327. 5.2.2.5.3 For discharge to environmentally sensitiv e locations, use THPS ( Tetrakis hydroxymethyl phoshonium sulfate) which degrades to non-toxic components. 70% pure THPS shall be applied at 50 ppm THPS is also available as blends with other products which may be less environmentally friendly. The disposal plan for this treatment must be approved following SAEP-327. 5.2.2.5.4 Polyhexamethylene biguanide hydrochloride or PHMB) (SAP Material # 1000178704), may also be used in hydrotests at 200 ppm. The disposal plan for this treatment must be approved following SAEP-327. Commentary Note: ATROS TK-1, Troskil-1, is an example of this type of chemistry. 5.2.2.5.5 Other biocides may be used if approved by the Supervisor, Petroleum Microbiology Unit, Material Sciences R&D Division, R&DC and if approved by Environmental Engineering Division, Environmental Protection Department, per SAEP-327. Ensure that the biocide does not react with oxygen scavenger before using. In cases of doubt, contact Supervisor, Corrosion Technology Unit, Materials Engineering & Corrosion Control, CSD. THE END

Page 6 of 12


Rev 3


SAIC NUMBER

SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

Attachment 3 - LAY-UP FOR CARBON STEEL SYSTEMS Dry Lay-up 5.2.3.1 Dry lay-up may be achieved using several different drying media. These include hot dry air, controlled dew point inert gas, and drying chemicals such as glycol or methanol applied between two pipeline scrapers or as a gelled scraper. The best results may be achieved by using a combination of these techniques. Safety Note: See Paragraph 10 on safety issues. 5.2.3.1.1 Dry lay-up using hot or dew point controlled air may only be used for systems where the dew point can be successfully reached within 1 week. Longer drying periods using air may contribute to the generation of excessive quantities of corrosion products in lines. Therefore, dry lay-up using air is only appropriate for systems that can be easily dried. One means to assure effective drying within req'd times is to limit lengths of systems being hydrotested. 5.2.3.1.2 Sweet gas may be used for dehydration. However, before using sweet gas e nsure that hydrate formation will not be a problem. Hydrate formation may occur at low temperatures & elevated pressures. 5.2.3.2 Remove the hydrotest water from the system. For facilities other than pipelines, drain the system completely, sweep & mop as required to ensure that no visible traces of water remain. For pipelines, dewatering shall be performed by scraping with a three or four cup displacement scraper or better system such as a gelled scraper. Scrapers shall be driven by nitrogen or sweet gas unless the use of dry air has been preapproved. 5.2.3.3 When seawater or similar high salinity water has been used as the hydrotest media, remove salts from the metal surface by rinsing with a low-salinity water containing less than 4,500 ppm total dissolved solids. For pipelines, use a slug of low salinity water between two scrapers to rinse salts from the walls. Size of t he slug will be dependent upon the length of the line. More than two scrapers may be required in cases where a large slug of water is required. Present calculations and assumptions made to justify size of slug to be used. The use of seawater/high salt hydrotest water in fa cilities under the responsibility of Pipelines Department must be pre-approved in writing by Pipelines Dept, General Supervisor, PTSD, and the responsible area Manager. For equipment that is under the responsibility of other Departments, the use of seawater/high salinity water must be pre-approved in w riting by the local corrosion engineer. All mitigation actions shall be presented for approval at design stage prior to commencement of construction or it will not be a permissible option once construction has commenced. ACTION REQUIRED (TYPICAL) 5.2.3.4 If using inert gas drying for a pipeline, first, remove remaining water with methanol or glycol slug between two scrapers, in order to achieve drying in a short period. Then dry with dehydrated inert gas. Gelled chemicals may be used. Ensure compatibility of dehydrating chemicals with all material in system. 5.2.3.5 If at all possible, hydrotests should be performed with the valves removed from the line. However, if this is not possible, valves must be carefully dewatered. As the final stage of dewa tering process, remove water from pipeline valves and all other valves that may be damaged by trapped hydrotest water by blowing through the top drain with nitrogen and displacing fluid out of the bottom of the valve. Do not open or close valve during this dewatering sequence. When the bulk of the w ater has been removed, blow vapor phase corrosion inhibitor Cortec VpCI 309 or equivalent with nitrogen until it is visibly discharged at the bottom of the valve. 5.2.3.6 Immediately after dewatering, start drying system to a dew point that will ensure a dew point of of -1°C or less at the final lay-up pressure at all exit points. Dry by blowing sweet gas, nitrogen, or, if pre-approved, heated dry air through the system for not less than 12 hours to allow any remaining moisture to come to equilibrium with the dry air. Check and ensure that all measurement locations are at or below the required dew point. Repeat the drying procedure if the measured dew point at any one location is above the set limit. For pipelines, dew point readings must be done at the beginning, end, & all mainline valve locations. Record dew point temperature readings at each test location. Record the pressure of the line or system at the time of the dew point measurement. Record pressure at which the dew point measurement is made if different to the actual system or line pressure. If the dew point temperature is derived at a different pressure to lay-up pressure, use App. 2 or equivalent conversion charts to yield dew point at lay-up pressure. Safety: See Para 10.5.1 on separation of air & gas mixtures.See Para 10.5.2 on safety issues concerning nitrogen. 5.2.3.7 When required dew point is reached, pressurize the system with nitrogen or sweet gas to final lay-up pressure. Dry air may be used only if it has been pre-approved. Systems shall be maintained at a positive pressure of at least 30 psig unless this exceeds the design pressure of the system. Pressures up to the normal operating pressure have been used for lay-up for some systems. The dew point at the final lay-up pressure must be lower than -1°C. 5.2.3.8 Shut in the system, maintain and monitor the pressure per 5.2.2.4 during the lay-up period. 5.2.3.9 For pipelines, re-measure dew point at all original test locations one week after reaching final lay-up pressure. If any dew point reading is found to be higher than -1ºC at the lay-up pressure, then the entire line must be dried again or an alternative preservation method must be implemented. THE END (DRY LAY-UP)

Page 7 of 12


Rev 3 SAIC NUMBER


SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

Attachment 4 - LAY-UP FOR CARBON STEEL SYSTEMS INERT GAS LAY-UP 5.2.4.1 Displace the hydrostatic test water by positive pressure with nitrogen or sweet gas until no water drains out of the system. Shut in the system under positive pressure until commissioning and start-up. Ensure that systems being drained have vacuum relief valves and pressure relief v alves as necessary to protect the system. 5.2.4.2 For pipelines, displace water by scraping with a three or four cup displacement scraper or better system such as a gelled scraper. 5.2.4.3 Microbial control per paragraph 5.2.2.5 is not required even though some residual water is left in the system.

AMBIENT LAY-UP (SEE ATTACHMENT 7, SPECIAL VALVE NOTES) 5.2.5.1 Use ambient lay-up only if all of the following conditions apply: a. Drains are available at all low points to ensure complete removal of water. See ATTACHMENT 7 Notes b. Corrosion allowance has been provided, c. Pitting can be tolerated; and d. Particulate rust can be tolerated. 5.2.5.2 Remove all water from the system. For facilities other than pipelines, drain the system completely, sweep and mop as required to ensure that no visible traces of water remain. For pipelines, dewatering shall be performed by scraping with a three or four cup displacement scraper (or better) unless system limitations make this option impracticable. 5.2.5.3 After removal of all water, close the system to prevent the entry of sand or rainwater. 5.2.5.4 Install a vacuum breaker unless it is demonstrated that the system will not collapse under vacuum.

OTHER LAY-UP (SUCH AS VALVE CORROSION PREVENTION) Other lay-up methods are acceptable with the prior written approval of the Supervisor, CTU/ME&CCD/CSD, and, in cases where safety concerns may arise, t he approval of the Chief Fire Prevention Engineer, Loss Prevention Department.

THE END

Page 8 of 12


Rev 3 SAIC NUMBER


SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

ATT. 5 - LAY UP PROCEDURE (SPECIAL APPLICATIONS) Dry Gas & Refined Hydrocarbon Product Pipelines & Piping* 7.3.1 Hydrotest procedures for services in these categories under Pipelines Department jurisdiction shall be reviewed and approved by Pipelines Department: specifically, the General Supervisor, PTSD, and Manager of the respective area department. *This piping can extend into Plant Piping (ASME B31.3) 7.3.2 Prevent corrosion during hydrotest & lay-up procedures for sweet sales gas, ethane, refined products such as gasoline, kerosene, diesel, etc, and processed NGL. Corrosion products and other contaminants introduced during construction, hydrotesting, and start-up can create major problems for many years. 7.3.3 Remove all debris f rom line before hydrotesting using brush scrapers and magnetic scrapers. 7.3.4 For pipelines and piping in dry gas or refined hydrocarbon product service, oxygen scavenger shall always be added to the hydrostatic test water, even when the hydrotest water contact time is less than 14 days as specified in Para. 5.1. This does not apply to plant piping which shall be treated per Para. 5.1. Use batching scrapers and/or a slug of nitrogen to separate the air in the system from coming in contact with treated water, and then fill the system with treated water by injecting sufficient oxygen scavenger to maintain a minimum oxygen scavenger residual concentration of 20 ppm and an oxygen concentration less than 10 ppb. 7.3.5 Pipelines in dry gas or refined hydrocarbon product service shall be layed up using eit her the wet lay-up method per Paragraph 5.2.2 or the dry layup method with the line pressurized with dry sweet gas or dry nitrogen, but not air. 7.3.6 When water is finally removed from the pipe, either at the end of the hydrotest or at the end of a wet lay-up, the system shall be thoroughly dried. Air drying shall not be used f or pipelines. Air drying may be used for small in-plant piping systems if drying can be completed in no more than one week. Refined product lines which are generally small (about 14" or less) may be dried with nitrogen from skidmounted nitrogen generation units or from bulk tanks. Sweet gas pipelines that are generally large diameter will most usually be dried with sweet gas if available. Chemical desiccants such as glycol or methanol may also be used if necessary and specifically pre-approved in the hydrotest procedure. 7.3.7 An alternative to extensive drying operations & detailed hydrotest control is to use internal coatings to prevent corrosion and black powder formation. This decision must be taken early in the design process. Evaluate the economics of coating versus the economics careful hydrotest control. Obtain approval of the coating from the Supervisor, Cathodic Protection and Coatings Unit, Materials Engineering and Corrosion Control Division, CSD. Obtain approval of coating and hydrotest procedures from the Pipelines Dept: General Supervisor, PTSD, and Manager of the respective area department.

SOUR GAS & SOUR OIL PIPELINES 7.4.1 Hydrotest procedures for sour gas, sour oil, or sour multiphase lines under Pipeli nes Department jurisdiction shall be reviewed & approved by Pipelines Dept: specifically, the General Supervisor, PTSD, and Manager of the respective area department. 7.4.2 After the pipeline has been hydrotested, it shall be layed up following methods detailed in Para 5.2. 7.4.3 Prior to the introduction of sour process fluid into a new line, the line shall be dried. Drying is not required for existing lines. 7.4.4 Immediately prior to recommissioning new or existing lines, lines shall be batch treated with a corrosion inhibitor by using a slug of corrosion inhibitor between two or more scrapers. Slug size is calculated as follows: Gallons of inhibitor = Pipeline length (km) x pipeline diameter (in) x 3 7.4.5 Where there is an unavoidable delay between signature of the Mechanical Completion Certificate & introduction of fluids into the line, PMT shall provide sufficient funds to operating or other organization that will perform the inhibitor treatment to pay for all expenses associated with the inhibitor treatment. THE END

Page 9 of 12


Rev 3 SAIC NUMBER


SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

ATTACHMENT 6 - LAY UP PROCEDURE (PLANTS- SPECIAL APPLICATIONS) Applications are for Plant Piping Systems & Equipment as clearly specified below. 7.5 Plant Piping 7.5.1 In general, new or existing pipework in plants & refineries will be hydrotested either on-site or in a plant fabrication shop. Due to the shorter physical length of this equipment, hydrotests can be effected in a shorter time than that which would require chemical treatment with oxygen scavengers or biocides per Para 5.1, 6.3, or 5.2.2. Therefore, unless these time limits are exceeded, no chemical treatment is req'd. 7.5.2 Due to the complexity of plant construction operations, often new plant pipework is laid up by drying following the requirements of 5.2.3 to achieve a dew point of -1°C. Drying is normally achieved within a plant using dry air or sometimes nitrogen. 7.5.3 Chloride limits for 3xx-series stainless steels must be strictly followed. 7.6 For any galvanized pipe not covered by Paragraph 7.2, treat galvanized steel pipe per paragraph 5.1 and lay-up per paragraph 5.2. 7.7 Water shall not require treatment if used to pressure test completely internally coated or lined equipment, or systems entirely fabricated with non-metallic materials. No lay-up procedure is required for totally non-metallic systems (e.g., PVC pipe). 7.8 Lube oil systems shall be pressure tested following the reqmts of SAES-L-150. Water shall not be used. 7.9 Instrument air systems shall be pressure tested following requirements of SAES-J-901 & SAES-L-150. Water shall not be used. 7.10 Boilers shall be laid up per SAEP-1026. 7.11 For heat exchangers, lay-up shall be required unless start up occurs within 14 days of commencing the hydrostatic test. 7.12 For yard or shop fabricated piping systems that are constructed abroad, hydrotested, then shipped to Saudi Arabia, PMT shall submit the hydrotest and layup procedure to the Supervisor, CTU/ME&CCD/CSD, for approval. In addition to one of the lay-up methods from Paragraph 5.2, the use of vapor phase corrosion inhibitors shall normally be required. 7.13 For all materials not specifically covered in this standard and for doubtful situations, obtain prior written clarification from the Supervisor, CTU/ME&CCD/CSD.

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. 8.3 Monitor chemical injection rates on site using displacement gauges.

9 Disposal 9.1 Hydrostatic test waters m ust be disposed per SAEP-327 and SAES-A-103. 9.2 Disposal plans must be approved prior to the start of any hydrotest.

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. 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 = suffocation. Page 10 of 12



Rev 3 SAIC NUMBER

SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

ATTACHMENT 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT) STAINLESS STEEL SYSTEMS & EQUIPMENT (OPTION B) STEP # 1 (Oxygen Scavenger Rule) 6.3 Treat the hydrostatic test water with oxygen scavenger per paragraph 5.1* if the equipment contact equipment contact time with water might exceed 4 days. Oxygen Scavenger Appendix is in Attachment 8. 5.1 Treatment of Hydrostatic Test Water When equipment contact time with hydrotest water may exceed 14 days, an approved oxygen scavenger (Appendix 1) shall be added to the hydrostatic test water. Treat the water before it enters the system. Use batching scrapers and/or a slug of nitrogen to separate the air in the system from coming in contact with treated water, and then fill the system with water injecting sufficient oxygen scavenger to maintain its residual concentration at greater than 20 ppm and an oxygen concentration of less than 10 ppb. STEP # 2 (Apply Lay-Up Method using 30-day rule). See Special Notes Below. 6.4 Lay-up the system following the requirements of Paragraph 5.2*. Note: A Lay-up Method is selected. 5.2 Lay-up Procedures 5.2.1 Equipment must be laid-up after hydrotesting unless it can be ensured that it will be returned to service within 30 days from the first introduction of hydrotest water to the system. Use one of the lay-up methods detailed (Wet, Dry, Inert Gas, Ambient, Other in ATTACHMENTS 2, 3, or 4). See Paragraph 7 for requirements for specific systems (Note: Attachment 5 Does not normally apply to SS Systems). Lay-up procedures for pipelines under the responsibility of Pipelines Department shall be approved prior to hydrotest by the General Supervisor, Pipelines Technical Services Division (PTSD), and by the Manager of the concerned area. Approval of lay-up procedures for other equipment shall be the responsibility of t he Saudi Aramco Engineering Superintendent or his designate (Note: Pipelines are not normally SS). STEP # 3 (End Lay-up and Evaluate Condition/Corrosion as Necessary) 6.5 At the end of the lay-up, commission and start up the stainless steel equipment within 14 days.

SPECIAL CARE FOR 13Cr (400 Series) Trim SS VALVES Trim 8 is the most common type of valve used in Saudi Aramco Plants. This requirement was specifically cited for Pipelines, as severe corrosion occurs with extended improper Lay-up. CSD has stated that this also applies for Plant Piping. This is common sense & must be addressed in Plant Piping Pressure Testing & Valve Field Testing & Subsequent Lay-up Actions as follows: 1. Valves coming from the manufacturer are pressure tested and "lay-up" is "OT HER" or Special: a) Valve manufacturers takes great care to stroke valves and allow water "time" to descend from bonnets b) Water is then blown out using high pressure air until water is removed. Moisture is still present. c) Valve Manufacturer "APPROVED CORROSION-RESISTANT LUBRICANTS" are then professionally applied by trained valve testing technicians who distribute lubricant in effective methods to prevent rust. d) Valves are then stroked and lubricants are spread evenly over sealing surfaces to prevent corrosion. e) Valves are then coated and sealed/covered shipped to Saudi Aramco for installation in our facilities. f) Valve handling during shipping and Other* Concerns (age in storage, corrosion consideration, damage) requires the Safeguard of "FIELD TEST ING OF CRITICAL ISOLATION VALVES" per SAES-L-108. g) Valves are then again opened & inspected for warranty coverage for shipping damage/other concerns. h) Valves are field t ested (body test, high pressure seat test, other tests as required by SAES-L-108). CORROSION CONTROL CONSIDERATIONS ARE NOW THE RESPONSIBILITY OF THE CONTRACTOR!!! At a minimum, Contractor Procedure SHALL: 1. Apply the same lay-up and care after Valve Testing that was applied by the Valve Manufacturer. This includes careful drying and application of lubricants and corrosion control measures applicable. 2. Perform routine "PRESERVATION CHECKS" when valv es (13 Cr trim or 400 series SS) are stored longer then 30 days after field testing to assure effective corrosion control measures. 3. IF OPTION B IS SELECTED AND THE VALVE IS THEN TESTED IN-LINE, CONTRACTOR SHALL NOT ALLOW AMBIENT LAY-UP OF VALVES (13 Cr Trim or 400 Series SS). WHERE VALVES HAVE NO DRAIN, COMPLETE REMOVAL OF WATER FROM VALVE CAVITIES "SHALL BE DEMONSTRATED" to comply with SAES-A-007, Para. 5.2.5.1 a). Valves may be removed after test and treated similarly to Valve Testing. NOTICE: PROCEDURE SHALL DETAIL THE METHOD USED TO ASSURE COMPLETE REMOVAL OF WATER FROM VALVE CAVITIES, CORROSION CONTRO L MEASURES & PRESERVATION CHECKS DURING LAY-UP. FOLLOW UP VALVE CHECKS FOR CORROSION DEMONSTRATE EFFECTIVE PRESERVATION (LAY-UP). Page 11 of 12


Rev 3


SAIC NUMBER

SAIC-A-2007


22-Jan-14

QR NUMBER

MECH-

ATTACHMENT 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT) SAES-L-105 Valve Trim Table (Page 2/2)

SAES-L-105 Valve Trim Table & Notes Note: 400 Series SS = those mat'ls designated as 13 CR

Page 12 of 12


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Verify Test Medium for Hydrostatic Testing & Lay-up PROJECT TITLE





REV. NO.




ACCEPTANCE CRITERIA

REFERENCE

MECH-

SYSTEM ID.

MH's SPENT

PASS

FAIL

N/A

NOTE : Water Quality (A nalys is & Tes ting ) mus t be carefully planned. Quality Manag ement Concern (r emote areas).

A1

Water quality of intended hydrostatic test waters was determined well ahead of actual testing dates so that alternative water sources may be identified if original source water fails to meet requirements.

SAES-A-007, Para. 4.2.1 S-PMG000-114Z-0003 Sec-6.1

A2

Water quality of hydrostatic test waters shall be reconfirmed by testing as close to the time of the hydrostatic test as practicable. Note: Maintain Detailed Quality records (updated test results).


A3

In cases where individual tanker trucks are used to supply a test, the water samples are selected from a representative* number of actual truck loads being delivered to the test site. (* per procedure)


A4

SAES-A-007, Water for hydrostatic test or lay-up shall have a sulfate reducing bacteria Para. 4.2.3 S-PM(SRB) count of 103/ml or less using RapidChek II Method or other G000-114Z-0003 COMPANY approved alternative tests (obtain approval letter). Sec-6.1

A5

Water for hydrotesting or lay-up shall be documented clean & free from suspended matter, by filtration capable of removing 99% of all particles (2.1 mil) in diameter & larger (270 mesh wire mesh screen)

SAES-A-007, Para. 4.2.5

A6

If the hydrostatic test water is to be reused, its SRB count shall be 103/ml or less using RapidChek II Method and has oxygen level of less than 20 ppb, or additional chemical treatment will be required. Oxygen levels tested using CHEMetrics Self-Filling Ampules for Colorimetric Analysis, dissolved oxygen test kit, K-7599 (0-100ppb)


B

Treatment of Hydrotest Water for CS & Low Alloy Steel Equipment (Contact time with water will exceed 14 days). (Exception: pipelines in dry gas or refined hydrocarbon product service per Item E3 below.)

SAES-A-007, Para. 5.1 S-PMG000-114Z-0003 Sec-7.1

B1

Page 1 of 4

TRAVEL TIME


General Requirements (Use SATR-A-2014 & SAIC-A-2007 & an Approved Lay-up Procedure with this checklist)

Hydrotest water is treated before it enters systems by addition of approved oxygen scavenger (below) at a feed ratio stated in the attached table from SAES-A-007, Table 1.

PLANT NO.



QR NUMBER




A

22-Jan-14

EQPT CODE


ITEM No.


RE-INSP DATE

B2

Batching scrapers and/or a slug of nitrogen separates the air in the system from coming in contact with the treated water during filling.


B3

Careful practice during treated water injection maintains the oxygen scavenger residual concentration at greater than 20 ppm & oxygen concentration of less than 10 ppb. Check injection set-up closely. Note 1: Monitor injection practices carefully. Injection of oxygen scavenger and other treatment chemicals is continuous at a rate that provides specified concentration during system filling. Note 2: Multiple treating chemicals to be used are compatible.


Page 2 of 4


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Verify Test Medium for Hydrostatic Testing & Lay-up PROJECT TITLE

ITEM No. C

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

Treatment of Hydrotest Water for Stainless Steel Equipment SAES-A-007, Para. 4.2.8 / SPM-G000-114Z0003 Sec-6

C1

Permanent written records of water supplied for testing stainless steels including test records & results are maintained by Contractor.

C2

Water tested has a dissolved chloride ion content (not chlorine) below 50 SAES-A-007, ppm. Seawater or high TDS water is prohibited. Para. 6.1.1/ S-PMNote: With prior written CSD approval, water up to 250 mg / Liter G000-114Z-0003 Sec-8.1.1 chloride ion is permitted (with special commentary restrictions)

C3

Test water is treated with oxygen scavenger per Section B of this checklist if equipment contact time with water will exceed 4 days.

D

Special Requirements & Specific Applications

D1

Carbon Steel Atmospheric Pressure Aboveground Storage Tanks require no test water treatment. Immediately after tests, draining & removal of test water (no visible traces) is required.

Coating consi derations ( s alts) s hall be cause for testing

SAES-A-007, Para. 6.3 S-PMG000-114Z-0003 Sec-8.1.2


D2

Potable water systems (raw, drinking water) shall be tested with FRESH Potable Water. Oxygen scavengers & biocides are prohibited in potable water systems. (SAES-S-070, Par.18.2 a) Important Note: New Potable systems are subject to disinfection requirements.COMPANY will perform testing before systems enter service. COMPANY recommends test water be treated with either chlorine or sodium hypochlorite to effect a residual chlorine concentration between 0.2 mg/L and 0.5 mg/L before service.

SAES-A-007, Para. 7.2.2 / SPM-G000-114Z0003 Sec-9.2

D3

Utility systems other than potable water utilize either Potable water, well water or sea water for tests. (SAES-S-070 Par.18.2 b)

SAES-A-007, Para. 7.2.1 / SPM-G000-114Z0003 Sec-9.2

D4

Galvanized piping systems not covered in D2 & D3 above, follow Section B of this checklist.


D5

Dry Gas Pipelines or Refined Hydrocarbon Product Services regardless of equipment contact tim e with water, utilize oxygen scavenger added to hydrostatic test water. Note: For Plant Piping (Dry Gas/Refined Hydrocarbon services) are treated per Section B of this checklist


D6

Sour Gas & Oil Pipelines utilize a test water (procedure) that has been approved by Pipelines Department, General Supv., PTSD.

SAES-A-007, Para. 7.4.1 S-PMG000-114Z-0003 Sec-9

D7

Internally coated or lined equipment and non-metallic systems (PVC) require no test water treatment.


Lube and seal oil piping shall be pressure tested with its own fluid.

SAES-A-007, Para. 7.8 S-PMG000-1360-0001 Sec-23.17a

D8

Page 3 of 4


22-Jan-14

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Verify Test Medium for Hydrostatic Testing & Lay-up

SAIC-A-2008

PROJECT TITLE


ITEM No. REMARKS:

ACCEPTANCE CRITERIA


REFERENCE

QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE

REFERENCE DOCUMENTS: 1. SAES-A-007,S-PM-G000-114Z-0003 Hydrostatic Testing Fluids and Lay-Up Procedures, S-PM-G000-1360-0001 General Specification fof Piping. 2.

SAES-L-150, Pressure Testing of Plant Piping and Pipelines, /S-PM-G000-1360-0001-General Specification for Piping

3.

SAES-S-070, Installation of Utility Piping Systems,


Company


Company PMT


T&I Witnessed


W or k Ve ri fi ed

T&I Witnessed

QC Record Reviewed

W ork Verified

T&I Witnessed

QC Record Reviewed

W ork Verified


QC Inspector





QC Supervisor





Y = YES

Page 4 of 4

N = NO F = FAILED


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Verify Test Equipment (Safety Assessment)


SAIC-A-2009

PROJECT TITLE

22-Jan-14





REV. NO.



QR NUMBER

MECH-


EQPT CODE

SYSTEM ID.


PLANT NO.


MH's SPENT

TRAVEL TIME

COMPANY USE ONLY SAUDI ARAMCO TIP NUMBER




ITEM No.

ACCEPTANCE CRITERIA

REFERENCE


PASS

FAIL

N/A

RE-INSP DATE

Note TEST EQUIPMENT SAFETY ASSESSMENT (Notes 1-7) ... Perform along with SAIC-A-2011. 1

On New & Existing Projects, Test Equipment shall be thoroughly inspected & certified for safety (new & existing test equipment). Responsible persons shall be Project QA/QC Mgr and designated Hydrotest Engineer and Mechanical Inspector(s).

2

Regular inspection/maintenance of appropriate test equipment is mandatory to assure Safety on Company Projects. Use of existing equipment is permitted if equipment does not exhibit signs of deterioration & is regularly inspected (Per Note 7) and meets GI-2.102 Safety Requirements. Recommended is use of corrosion inhibitor when equipment is not in use for long periods.

3

Check component corrosion & wear (especially small fittings, nipples, etc) on existing equipment, especially test pumps. A thorough visual exam includes accessible internal components (use mirror & sunlight technique), a UT exam or hammer test (never hammer pressurized piping). Perform this exam in presence of COMPANY Inspection for new projects just prior to testing existing manifolds. Fittings and components found with heavy corrosion or thinning (verified wall loss) shall be replaced. Heavily Corroded fittings give a dull sound when hammer tested (new steel = ringing sound). Perform UT on suspect fittings or replace ASAP.

4

Existing Manifolds proposed for use on projects without detailed code construction documents (Engineering calcs & Inspection) must be certified for fitness and safety. Existing test reports alone are not acceptable support documents. Code construction detail, calculations (SIS sheet), appropriate Inspection and NDE are necessary for Safety. Unknown piping schedules can be determined by using a UT Thickness meter. Ratings for most fittings are stamped/visible. W eld quality is verified by VT or RT. Test manifolds frequently used, older than two years and stored in ambient conditions are highly susceptible to accelerated internal corrosion and thinning of components due to corrosive nature of test waters used in many locations. Detail Manifold Arrangement Dwgs.

5

Fabricated test components (blinds, spools, welded couplings, etc) are of proper code construction, receive inspection and are properly identification/marked for their pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never allow uninspected noncode test component use. Components found unfit for testing (non-code, under thickness or schedule & without calculations, deteriorated, damaged, corroded) are reported and removed ASAP from Company Projects.

6

Manifold design shall include limiting factor for all components (isolation valves, piping, fittings, tubing, etc). that are calculated (by design) to provide a PRESSURE RATING of 20% above the maximum expected system for test. Isolation valves shall be one Class higher than systems tested. Example: Project's greatest System Class = Class 900, CS (Normal), pressure rating 2,220 psi (test pressure = 3,350 psi). A manifold is needed to meet COMPANY safety requirements. Step 1: Maximum test pressure for Class 900 systems = 2,220 x 1.5 = 3,330, round up to nearest increment of 25 = 3,350 psi. Step 2: Manifold minimum design pressure (manifold test pressure) SHALL = 3,350 x 1.2 = 4,020 psi. Step 3: Manifold isolation valve must be Class 1500 minimum (one class above Class 900) See ASME B16.34 Tables & Para 7.2 = a 110% pressurization rule for valve seat closure tests. Step 5: Components (piping, fitting, tubing, etc) are rated for 4,020 psi minimum and have engineering calcs to support their use. Manifolds without construction details (arrangement drawings) are not accepted until CERTIFIED & RATED for Safety.

7

Perform safety checks for Notes 1-6 at least yearly* & before the start-up of pressure testing on pro jects. *Observation: The Diving Industry requires appropriate test equipment maintenance inspections on an annual basis. Scuba Tanks are pressurized frequently to 3,200 psi, often on a daily basis. Annual inspections use remote visual means (fiberscope). Corroded Tanks are replaced before they fail. Pressure Testing equipment sees similar and even greater pressures and service use. Safety of Test Crews, Inspectors & personnel on Projects deserve similar consideration. Keep Test equipment in good condition (Coated as needed, clean, legibly rated for pressure, legibly marked "as inspected, and regularly inspected).

A

Test Manifold & Appurtanances (Piping, Fittings, Hoses) - Verify Test Package Content before Testing

A1

Manifold Arrangement Drawing(s) attests to equipment safety: A) Fabrication is per code construction with component details listed such (Class, size, schedule piping, type isolation valve, etc). B) Maximum Safe Test Pressure Rating based on limiting factor. C) Each test manifold is identified with a unique number (certificate) D) Shows actual arrangement including hose configuration used Note 1: Manifold permanent marking (unique ID #, pressure rating) is legible, traceable & certified for safety (Support documenation).

Page 1 of 4

G.I.-2.102, Para. 5.1.5.5 SPM-G000-15200007, Sec-6.4.4

A2

Manifold Design Pressure Rating (Compare SIS for manifold & the system to be tested) exceeds system test pressure by 20%.

Page 2 of 4

G.I.-2.102, Para. 5.1.5.5 Safety Note 6 SPM-G000-15200007, Sec-6.4.4


Rev 3


SAIC NUMBER

Verify Test Equipment (Safety Assessment)

SAIC-A-2009

PROJECT TITLE


ITEM No.

ACCEPTANCE CRITERIA

B

Verification of Actual Test Equipment Set-up (Manifold Arrangement)

B1

Test Set-up* matches actual Test Manifold Arrangement. 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 actual test as performed. In event of testing accident, Loss Prevention Dept must be able to use diagrams & sketches to recreate actual test set-up/conditions.

B2

G.I.-2.102, Blow down valve is adequately rated at higher class than system under Para. 5.1.5.3 Stest, and is installed to depressurize the system safely and is easily PM-G000-1520accessible to operator. (Safety Note 6, Isolation valve) 0007, Sec-6.4.2

B3

Temporary Test Piping, spools, fittings to equipment and hose connections have adequate* pressure ratings, as marked, stamped or documented in test pkg. (*Match/exceed test pressure)

G.I.-2.102, Section 4

B4

Hoses are adequately rated, in good condition, safely arranged (tripping hazards) and protected from Heavy equipment traffic.

G.I.-2.102, Section 4

B5

Paddles or spectacle blinds & other fabricated test items for isolation are at least the same code class rating of systems under test or have code calcs to support them. Safety Note 5

SAES-A-004 Para. 7.3 / S-PMG000-1520-0007, Sec-8.3.1

C

Test Relief Valve(s)

C1

Relief valve is located in the system under test and near the test pump with Isolation valves on the inlet and outlet of the relief valve sealed open during the test.

C2

C3

D

D1

REFERENCE

set to relieve at 5%* above the hydrotest pressure. *Note: Test pressures less than 85% of SMYS can have relief valves set at 10% above test ressure. Verif SIS sheets/calcs. Tested relief valve(s) with a tag stamped with the word "TEST", the set pressure, and date is checked. Stamp date validity is a period of one week for project pressure tests. Stickers are legible & valid. A roster is kept for Pressure Relief Valves (M&TE) on projects.

G.I.-2.102, Para. 5.1.2, SPM-G000-15200007, Sec-6

G.I.-2.102, Para. 5.1.5 - Para 5.5.1/ S-PMG000-1520-0007, Sec-6.4.5 SAES-A-004 Para 5.5.1 / S-PMG000-1520-0007, Sec-6.4.1

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 considerations) & hot weather create pressure testing problems with frequent popping of relief valves. For this reason, gage accuracy within 2% is best. Note 3: Careful handling of delicate instruments as test gages is practiced by test crews. No gage damage or mishandling is found.

Page 3 of 4

SAES-A-004 Para 7.1.5 / S-PMG000-1520-0007, Sec-8.1.5


22-Jan-14

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Verify Test Equipment (Safety Assessment)

SAIC-A-2009

PROJECT TITLE


ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

D2

Pressure gages and pressure recorders are calibrated within (1) month prior to test. Stickers applied indicate latest calibration date.


D3

Test gauge is located at bottom of any equipment/system under test to enable reading test pressures inclusive of hydrostatic head. Note: Locate test manifold (with gage) at low points in systems under test. One foot of water (30 cm) @ ambient temperature = pressure increase of .433 psi. (1-meter = 1.42, 10-meter = 14 psi).

G.I.-2.102, Sec.4 & SAES-A-004, Para 7.1.5 / SPM-G000-15200007, Sec-6.2

D4

All gages have a range such that the test pressure is within 30% to 80% of the full range.


E


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE

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

E1

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). Note: ASME V, Art 10, Man. App. 1, Table 1-1021 requires surface metal temp measurements during testing (detailed in procedure). Record maximum (direct sun) & minimum test temperatures.

SAES-A-004 Para 5.6.1 / SPM-G000-15200007, Sec-6.5.3

E2

Thermocouples are installed to obtain accurate pipe metal temperature measurements and to determine the acceptance of the pressure test where pressure variations due to test water temperature changes occur, such as in cross-country pipelines.

SAES-L-150, Para. 11.3 S-PMG000-1360-0001, Sec-25.6

REFERENCE DOCUMENTS: 1. SAES-A-004, / S-PM-G000-1520-0007, General Requirements for Pressure Testing, 2. GI-2.102, Company General Instruction-Pressure Testing Safely, 3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, S-PM-G000-1360-0001, General Specification for Piping. 4. Pro Forma Contract Schedule Q (Project Specific)


Company


Company PMT



QC Inspector Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

T &I Wi tn es se d


T&I Witnessed

QC Record Reviewed

Work Verified



QC Supervisor


W or k Ve ri fi ed





Y = YES

Page 4 of 4

Work Verified

N = NO F = FAILED


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Pre-Test Punch Listing of On-Plot Piping

SAIC-A-2010

PROJECT TITLE





REV. NO.




22-Jan-14

Piping-


EQPT CODE

SYSTEM ID.


PLANT NO.


MH's SPENT

TRAVEL TIME





ITEM No.

ACCEPTANCE CRITERIA

REFERENCE


PASS

FAIL

N/A

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

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

A1

Test Package has been verified to be approved and to contain the detailed elements of S-PM-G000-1520-0006, Sect 8 as detailed in SAIC- S-PM-G000-1520 A-2003. Use 0007 Para. 6.5.1 Attachments 1 & 2 of this checklist (quick reference).

A2

Pressure Testing Procedure is approved. Test application meets S-PM-G000-1520Company reqmts as checked against Pressure Test Matrix - Attach. 3 . 0007 Para. 8.1.1

A3

S-PM-G000-15200006, Construction & Special Process Control (per S-PM-G000-1520-0006 Section 8 Database) has been documented as complete* (ready for Punch Listing). Weld Database/ Welding, NDT, PWHT, BHT, PMI, Other Testing, is documented in pkg Schedule "Q" Procedure is followed regarding Test Pkg flow sequence. Attachment IV Para. 1.7

B

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

B1

B2

SIS shall be prepared for all individual units of plant equipment which in view of size, pressure rating and application are within the scope of Company Standards and general industry codes A Safety Instruction Sheet is prepared for each piece of process equipment. Each SIS shall include, in addition to tabulated information, all significant and unusual hazards, recommendations, unusual inspections and tests relating to the piece of equipment. References to be used in preparing the SIS include design drawings, vendor's drawings, vendor's certificates, and inspection reports. A) Pressure rating of flanges (per ASME B16.5 or other) B) Pressure rating of any valves used in isolation (ASME B16.34) Note: (Valve pressure ratings for seat closure = tested at 110% when valves are used for isolation) C) Other system components (Internal Coating pressure rating) may result in test pressure reduction APCS 102 = 3,000, others 5,000psi Test Pressure=2t(0.9)(SMYS)/D where: t= nominal pipe wall thickness minus the specified mill tolerance* *mill tolerance =12.5% (seamless pipe) or .01" for welded plate SMYS= Specified minimum yield strength (psi). Use ASME B31.3 Appendix A Tables for specific material grade used (SIS sheet). Example: SMYS for API 5L Gr X-60 = 60 KSI or 60,000 psi D = Outside piping diameter (OD)* ... Per ASME B36.10 Tables *Note: For nominal piping sizes 14" (& above), actual O.D. = 14" For nominal pipe sizes 12" & below ... See ASME B36.10 Tables

Page 1 of 10

SAES-A-005 Para 4.2

SAES-A-005 Para 5.1

RE-INSP DATE


Rev 3



SAIC-A-2010

PROJECT TITLE

ITEM No.

SAIC NUMBER

22-Jan-14


ACCEPTANCE CRITERIA

REFERENCE

PASS

On SIS sheets, proposed hydrostatic strength test pressures for EXISTING PLANT PIPING SYSTEMS (TIE-INS) is the test pressure shall be minimum required by the Code ASME B31.3. Actual min wall thickness of piping shall be verified (PROCEDURE) and used in such calculations. Thickness readings are current (30 days) & flange rating is considered when calculating test pressure (ASME B31.3) B3

C

Test Pressure=2t(0.9)(SMYS)/D where: t= ACTUAL PIPING WALL THICKNESS (MINIMUM MEASURED) SMYS= Specified minimum yield strength (psi). Use ASME B31.3 Appendix A Tables for specific material grade used (SIS sheet). Example: SMYS for API 5L Gr X-60 = 60 KSI or 60,000 psi D = Outside piping diameter (OD)* ... Per ASME B36.10 Tables *Note: For nominal piping sizes 14" (& above), actual O.D. = 14" For nominal pipe sizes 12" & below ... See ASME B36.10 Tables

SAES-A-005 para 5.1

Punchlisting Field Walkdown (Pressure Piping Systems):

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

C1

All joints (flange, threaded, welded or mechanical seals) are left exposed for visual leak detection during the strength test. S-PM-G000-1360 A) External coating & priming of joints is allowed only if approved by 0001 Para. 23.16 Company. B) The pipe itself can be externally primed & coated to a final coat.

C2

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

SAES-L-450, Para. 9.4

C3

Drains shall be provided at all low points of the piping system. Note: Exceptions are submarine & buried* pipelines (*pump-outs)

S-PM-1520-0007 Para 8.4.2

C4

Vents and drain valves, both temporary and permanent, conforms with the piping class or rating. ( Refer SAES-L-108)

SAES-L-105, Para. 5.9/ S-PMG000-1360-0004 Sec. 12

C5

Supports are installed. Additional temporary support may be installed as required.

SAES-L-150, Para. 6.3/ S-PMG000-1520-0007 Para. 8.5.2

C6

Expansion joints and spring hangers or spring supports are provided with S-PM-G000-1520temporary restraints. 0007 Para. 8.1.6

C7

C8

C9

Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity, uneven weld profiles, and undercut) shall be removed by grinding and inspected by magnetic particle or liquid penetrant method. Temporary welded attachments to the pipe were ground off and inspected by magnetic particle or liquid penetrant method .

All threaded joints and faying surfaces shall be seal welded by a continuous fillet weld (required weep holes shall be left unwelded).

Page 2 of 10

S-PM-G000-15200011 Para. 13.5

S-PM-G000-15200011 Para. 13.6

S-PM-G000-15200011 Para. 13.14.1

Piping-


FAIL

N/A

RE-INSP DATE


Rev 3


SAIC-A-2010

PROJECT TITLE

ITEM No.

C10

C11

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

Isolation valves are verified to have been body and seat tested prior to installation through verification of field test certificates.

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

SAES-L-108, Section 4.7/ SPM-G000-13600001 Para. 23.11

S-PM-G000-15200007 Para. 9.1.3

C12

During filling, permanent vent valves are in open position. Plugging is only AFTER WATER FILL & EFFICIENT AIR VENTING .

C13

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

C14

Disc of check valve is removed, unless check valve has by-pass. Method for storage (plastic bag & tie) allows visual verification.

S-PM-G000-15200007 Para. 8.4.3

Spare taps of orifice flanges are plugged and seal welded.

SAES-L-110, Para. 8.2/ S-PMG000-1360-0004 Para. 17.3

C15

C16

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

S-PM-G000-15200007 Sec. 9.1.1

PM-G000-15200007 Sec. 8.4.2

S-PM-G000-13600004 Para. 17.3

C17

Process instruments and equipment that may be damaged by the strength test pressure are disconnected.

S-PM-G000-15200007 Para. 8.1.4

C18

The pressure testing manifold is separately pressure tested to at least 1.2 times the system test pressure but not less than the discharge pressure of the pump used for the pressure testing.

S-PM-G000-15200007 Para. 6.4.4

C19

Buried pipeline are adequately bermed or covered to anchor the line during pressure test.

SAES-L-450 Appendix C/ SPM-G000-13600001 Para. 23.17(b)

C20

Pressure gages and pressure recorders are calibrated within one (1) month before the test. C heck s ticker s at the time of the tes t.

S-PM-G000-15200007 Para. 8.1.5

C21

Paddle or spectacle blinds shall be used to isolate test sections. Safety of test "implements" has been checked (SAIC-A-2009)

S-PM-G000-15200007 Para. 8.3.1

Page 3 of 10


22-Jan-14

Piping-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER


SAIC-A-2010

PROJECT TITLE


ITEM No.

C22

C24

ACCEPTANCE CRITERIA

REFERENCE


22-Jan-14

Piping-


PASS

FAIL

N/A

RE-INSP DATE

S-PM-G000-15200007 Para 6.4.2

A bleed valve readily accessible is provided in case immediate depressurization is required.

Components in new piping systems which interfere with filling, venting, draining or flushing shall not be installed until after line flushing and pressure testing are completed. These include orifice plates, flow nozzles, sight glasses, venturies, positive displacement and turbine meters and other in-line equipment.

S-PM-G000-15200007 Para. 8.1.4.

REMARKS: REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 2. SAES-L-105, Piping Material Specifications, (30 March, 2005) 3. SAES-L-108, Selection of Valves, (21 December, 2005) 4. SAES-L-110, Limitations on Pipe Joints and Components, (18 May 08) 5. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (16 May 07) 6. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) 7. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005) 8. SAES-A-005, Safety Instruction Sheet (28 february 2005) 9. S-PM-G000-1360-0001, General Specification for Piping 10. S-PM-G000-1360-0004, Piping Material Specification 11. S-PM-G000-1520-0007, General Requirements for Pressure Testing 12. S-PM-G000-1520-0011, Welding Requirement for On-Plot Piping 13. Schedule "Q", Company Quality Requirements


Company Company PMT

Construction Representative* Name, Initials and Date:

Work is Complete and Ready for Inspection:

QC Inspector Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T &I W it ne ss ed


Work Verified

T&I Witnessed

QC Record Reviewed

W ork Verified



QC Supervisor Name, Sign and Date:






Y = YES

Page 4 of 10

N = NO F = FAILED



Rev 3 SAIC NUMBER

Pre-Test Punch Listing of On-Plot Piping

SAIC-A-2010


22-Jan-14

Piping-

Attachment 1 -- S-PM-G000-1520-0006 Section 10 (Test Pkg Minimum Content)

Page 5 of 10



Rev 3 SAIC NUMBER

Pre-Test Punch Listing of On-Plot Piping

SAIC-A-2010


22-Jan-14

Piping-

Attachment 2 -- NEMA TC 2 (Type EPC-40-PVC) Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No

Test Pack Preparation


Engineering

Contractor QC


Contractor QC

Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

PID


Pressure Testing

Construction

Contractor QC

SAPMT

PID

Proponent

System Lay-Up

Construction

Contractor QC

SAPMT

PID


Construction

Contractor QC

SAPMT

SAPMT

PID

Proponent

Clear 'A' Items




S. Aramco Final Insp for MCC

Page 6 of 10


Rev 3


SAIC NUMBER

SAIC-A-2010


22-Jan-14

Piping-

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








Underground Process Piping Flare Lines (24" & above)


A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum of 2 hrs B) If justifiable (safety) & line must be back-filled, a 24 hr recorded test (Chart Recorder) reqd.




Vacuum Piping




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

SERVICE TEST 30 mins (min) Soap Bubble Leak Test at 5-10 psig

Existing Plant Piping Incl. Tie-Ins


RETESTING REQMTS

See Notes




See Notes



Open-Ended Piping

EXEMPT, VISUAL EXAM











Page 7 of 10


Rev 3


SAIC NUMBER

SAIC-A-2010


22-Jan-14

Piping-

Sampling Lines

See Note



See Note



Skid-Mounted EXEMPT IF TESTED BY VENDOR 1. When testing with adjacent Lube oil system piping (no leaks = acceptance). 2. When code repairs are m ade to skid-mounted piping to correct misalignment, per 01-SAMSS-010 Piping (Vendor) (exceptions noted)

physical damage or any modifications in-situ, pressure test the affected spools.


See Note

See Note


Exemption Procedure

See Note


See Note


(Checklist Item D4)

See Note




Page 8 of 10



Rev 2 SAIC NUMBER

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2010

22-Jan-14

Piping-

Attachment 4 - SPEC CHECK INSTRUCTIONS 1) Test Package Review Tool & Special Process Clearance Verification BEFORE Hydrotest. a. Use Spec-Check along with SAIC-A-2003 (Checklist for Hydrotest Package Review) & this checklist. b. Check test package Bill of materials against piping line class requirements (See sample Spec Check) c. Check NDT requirements in SPEC-CHECK against NDT enclosed in given test packages. Check for correct NDT extent specified and correct NDT methods. Check NDT reports and compare RT field markings to the test reports. d. Check RT reports closely for repairs (repair shots, penalties) & field verify the markings exist on the correct joint. Note: If discrepancies exist, simply review the film and follow NDT checklists for RT (Clear direction exists here). e. Shop/Field Weld NDT requirements vary and need to closely checked for omission of work. (10% shop, 100% fld) f. Check PWHT reports against material spec requirements (service, thickness, etc). Verify visually PWHT was done g. Check BHT reports against spec requirements (sweet & sour services). Verify roundness of Brinnell indentation. h. PMI OK markings exist on those joints PMI examined. Verify markings to correct joint. i. Check color codings of materials to assure correctly specified material was used in piping systems. 2) Check field installations (Pre-Hydro Walkdown, Surveillances) for following special processes: a. Gasket Installation – HOLD POINT FOR CONTRACTOR - Visual before installation, Color code Table CRITICAL: COLOR CODES EXIST FOR ALL GASKETS (TABLE COVERS ALL GASKETS IN ALL LINE CLASSES) b. Bolting Installation & Torque (Bolts, Nuts, Lubricants, Friction Factors, See Torque Tables) c. Valve Installations (Check Valves installed against SAES-L-105 Spec T able Attached) d. Piping specs and piping schedules cab be included e. Check Spectacle plates, blinds, spacers, Jack screws, etc for SPECIFIC SASD DRAWING conformance. f. Check miscellaneous material elements (Class & pressure ratings for weld bosses, fittings) & Limitations (L-110) g. Check W PS and any special instructions needed per welding (invaluable tool for Control) 3) Perform FOCUSED ASSESSMENTS with both CHECKLISTS & SPEC-CHECK 4) Perform Focused Assessments with Spec-Check alone on all specified Materials 5) Perform Focused Assessments with Spec-Check alone on Special Construction Processes. 6) Perform Post-Hydro Checks “in the field” (Reinstatement, FEIL, Pre-Commissioning, Commissioning) a. During Reinstatement, Use Spec-Check along with SAIC-A-2010 (Checklist for Hydrotest Reinstatement) to ensure correct installation (Bolting, valves, etc) b. During FEIL walkdowns, use Spec-Check during accumulation of Field Exception Items List (FEIL) c. During Final walkdowns, use Spec-Check one last time (Pre-Commissioning, Commissioning) 7) Add notes for: WPS Review/Compilation after Review of Line Class Tables, Valve Spec codes, flanges, special walk down notes, supports, etc by using a numerical code and hand written notes on back! SPEC-CHECK can be modified for any item. Ensure the best quality on your project! Check all specs

Test Package Review Notes 1. Check status sheet for signoffs. 2. Check Index against contents 3. Pressure Test Data Sheet • Check drawing numbers against actual enclosed • Check excluded equipment & especially if there are any P&ID notes • Check pressure test value proposed to assure limiting factor is correct (usually a flange) 4. Do a Weld Tracker NDT report review (detailed) • Compare completed Special Process reports (RT, MT, PT, PWHT, BHT, PMI, etc) • Compare against list of outstanding NDT (Backlog of Penalty & Repairs) 5. Review P&IDs and isometrics against spec check for line class required materials (drawings often are in error) Note: Make note on cover in Punch list Accepted by PID “Field verify against Spec/B.O.M” This is especially critical for Sour Service & Special Service lines. Note: Ensure orifice flange reports are included & any NDT specified 6. Check hydrotest diagram • Manifold arrangement sketches must show all elements, & manifold construction/insp must be per SAIC-A-2009 Caution: Ensure test pressures do not exceed manifold element ratings (Valves are next size up for systems tested) Example 1: Class 300 # systems(1125 psi) would utilize a Class 600 Isolation valves in test manifolds at minimum. Example 2: A manifold with 800# gate valves will not be used in testing 600# systems (2250 psig) Reason: You are testing against the valve seat (closed position) & this is rated for 1.1 times test pressure, not 1.5. See Next Page for Spec Awareness (Basis for Spec Check on Projects) Page 9 of 10


SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Pre-Test Punch Listing of On-Plot Piping

Rev 2 SAIC NUMBER

SAIC-A-2010


22-Jan-14

Piping-

SPEC AWARENESS PID’s ATTENTION TO SPECS & SPEC-Check (Piping Line Class Specs, WPS, NDT Specs, PWHT, PMI, etc) on Projects: Initial Review of SPECS 1. Carefully recheck Contractor Piping Specs (Line Class Summary & Tables) as early as possible during or just after Design is com plete (as soon as they are issued and available). 2. This is done by checking Contractor’s specs against Line Class Material requirements listed in SAES-L-105. Give special attention to critical systems & systems above 300#. 3. Average large projects can have as many as 50 different piping specs & details can be very hard to pick up in the field. Pipelines have fewer specs and are easier to manage. THIS INCLUDES THE MAZE OF GASKETS!!! 4. Time tak en for early review only takes an experienced plant inspector 2 days of review. Findings (often human error) can be cr itical. Help prevent unplanned shutdowns on your projects & find substandard m aterial specs before they are installed or before they enter service. 5. Carefully check Contractor Special Process SPECS (WPS, NDT, PWHT, etc) as early as possible (as soon as they are issued and available). 6. This is done by checking Contractor’s Special Process Specs against code and SA requirements (SAES-W-011, Sect 17 for NDT & 13 for PWHT). SAES-W-012 is similar to SAES-W-011 in this respect 7. Ensure that notes are included in these SPECS that require increased NDT based on “field welding” and other code considerations. 8. Clear violations such as our “weekly highlight example” (such as specs and drawings that use 3000# fittings on a 900# system instead of required 6000# fitt ings) must be item ized & brought to SAPMT attention early. See attached Sample Weekly Highlight. 9. After all SPECS submitted by Contractor are accepted ... “CREATE” your custom SPEC-CHECK (sample attached with instructions). Commentary: This is a valuable review and exercise for all inspectors. Have all inspectors trained in this task for self-reliance during future projects. This teaches critical lessons in Materials*, specification requirements* and substandard installation identification*. *FACT: MOST INSPECTORS ARE WEAK REGARDING KNOWLEDGE OF SPECIFICATIONS & ARE UNAWARE OF MANY CRITICAL REQUIREMENTS! SPEC CHECK PUTS THESE DOWN ON PAPER (BY SYSTEM)

Test Package Review & Pre-Hydro Walkdow 1. Follow-up (after initial specification review/approval) can also include checking ISO drawings and bill of materials against approved specs before Pre-Hydro Walkdown 2. USE YOUR CUSTOM “SPEC-CHECK” “ SPEC-CHECK” on every new plant project as the perf ect walk down and test package review tool. Important Note: Never assume drawings or test packages are correct. Never assume NDE % & PWHT, PMI, etc performed/not performed by contractor is correct. Inspectors must be taught a systematic review method for test packs with focus on Specs. A thorough test package review system is a page by page page review that takes only 15 minutes per package & checks every page and every weld & all materials for com pleteness/correctness. Omission of Special Process work by Contractor is widespread & frequent, most often unintentional and simply due to a lack of AWARENESS.

Surveillance & Focused Assessment 1. Use SPEC-CHECK on routine surveillance. 2. Create a custom SPEC-CHECK for focused assessments on Valves. Incorrect valve installation is very common with valves placed in the wrong service (swapped, mislocated, mismark) 3. Create a custom SPEC-CHECK for focused assessments on small diameter piping (UT purposes). Past projects have seen as many as 20% of all piping segments installed of the wrong schedule of of piping (J-80, RT Refinery). I visit projects and find numerous substandard installations very often (human error, again). On your project, order/request/perform/get Contractor to do random checks of small diameter piping segments (2” & below). I do it myself with a 2-man crew with me, piping schedules in hand on all my projects & run at about a 2% reject rate. 4. Create a custom SPEC-CHECK for focused assessments on PWHT & BHT. Past projects have seen poor practice with failure to follow 12-step BHT procedure per NACE RP-0472 App A. 5. Turn your project surveillance into an effective and efficient Inspection asset that is valuable to Projects.

SHARE SPEC CHECK WITH YOUR CONTRACTOR FOR QUALITY Page 10 of 10


Rev 3 SAIC NUMBER

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Inspection of Pressure Test Preparation

SAIC-A-2011

PROJECT TITLE





REV. NO.




QR NUMBER

22-Jan-14

MECH-


EQPT CODE

SYSTEM ID.


PLANT NO.


MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY SAUDI ARAMCO TIP NUMBER




ITEM No. A

A1

ACCEPTANCE CRITERIA

REFERENCE

A3

Pressure Test Package meets Attachment 1 minimum content requirements. (Reviewed/approved/signed). (Reviewed/approved/signed). See SAIC-A-2003. Note 1: Package contents were reviewed carefully. Note 2: Document deficiencies are noted in package for action.

cleared & accepted* (*Test Pkg Flow Chart is also signed off) 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 be disturbed after the pressure test are marked/identified and tightened & QC records are per approved als o S A IC -L-2 014 & S A TR -L-2 001. procedure & available. S ee als

System Flushing and internal Cleanliness is complete. Test Package A4

Flow chart is signed-off. New systems and equipment in Plants were cleaned per approved procedures per SAES-L-350.

SAEP-1160, Section 8 SPM-G000-15200006 Sec 10 SAEP-1160, Section 8 S-PM-G000-15200006 Sec 10


SAES-A-004, Para. 7.1.2 S-PM-G000-15200007 Sec 8.1.2

Component Safeguards (temporary removals/test exclusions) exist for A5

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

SAES-A-004, Section 7

SAES-A-004, Para. 7.5.2 S-PM-G000-15200007 Sec 8.5

A6

Temporary supports are installed if they were determined to be required per SAES-L-150.

A7

SAES-L-150, Expansion joints and spring hangers or spring supports are provided with Para. 6.4 Stemporary restraints where needed to prevent excessive travel or PM-G000-1520deformation under the test loads. (Field Verify) 0007 Sec 8.1.6

A8

All joints including welded joints are accesible and left exposed for visual leak detection during the strength test. Note: This excludes joints subject to 24-hr recorded test

A9

PASS

FAIL

N/A

Test Preparation - General Requirements ... USE SATR-A-2001, SATR-A-2001, 2002, 2003, 2004, 2005 & SATR-A-2006 SATR-A-2006 as req'd.

Pre-Test Punchlisting is complete (per procedure). All "A" items are A2


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

Page 1 of 8

SAES-L-150, Para. 7.3 G.I.-2.102, Para. 5.6

RE-INSP DATE

Equipment & appurtenances (Attachments, auxilliary equipment, etc) A10 that are not adequate for test pressures are isolated from test.

G.I.-2.102, Para. 5.7 S-PM-G000-15200007 Sec 8.2

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 = 1.1 times valve press rating) A11 b) Open isolation valve drain (or nearest adjacent low-point drain) c) Relief valves placed on both sides of isolation valve. (Para. 7.3) d) Personnel are posted during testing t o identify any valve leak-by. e) Personnel control/stop pressurization (Valve leak-by evidence).

G.I.-2.102, Para. 5.7, Para 7.3 S-PM-G000-15200007 Sec 8.3

See Remarks Section (Safety Note 1) MSDS or Chemical Hazard Bulletins i s available/reviewed for all A12

chemicals handled (corrosion inhibitor, bactericide, chlorine, oxygen scavenger, etc). Written procedure to safely handle chemicals during testing & to ensure proper disposal after testing is approved.

Page 2 of 8

G.I.-2.102, Para. 5.9


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Inspection of Pressure Test Preparation

SAIC-A-2011

PROJECT TITLE

ITEM No. A1

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

Personal protective equipment (PPE) is available and utilized as

shown on these sheets and bulletins for chemical handling.

G.I.-2.102, Para. 5.2.1

A2

G.I.-2.102, Para. 5.1.11.1 SAccess/Egress for Test areas is marked & warning signs posted to alert PM-G000-1520approaching personnel of pressure testing activities. 0007 Sec 6.5.3.6

A3

Where a road parallels within 30 m (100 ft.) of an aboveground pipeline being tested, traffic shall be diverted or stopped during the test. If this is not practical, the area Loss Prevention offices should be contacted to confirm that the test can be conducted safely.

G.I.-2.102, Para. 5.1.11.5 S-PM-G000-15200007 Sec 6.5.3.6

A4

If non-Company facilities will be exposed in a pressure test of Company facilities, the proponent organization of the test shall so inform the Company Affairs representative prior to the test.

G.I.-2.102, Para. 5.1.12 S-PM-G000-15200007 Sec 6.5.3.6

A5

Copy of the approved pressure testing procedure & t he GI-2.102 are available at site. Test Personnel are safety trained/experienced.

B

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

B1

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 actual test as performed. In event of testing accident, Loss Prevention Dept must be able to use diagrams & sketches to recreate actual test set-up/conditions. Note 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.

SAES-A-004, Para. 5.6.1 / SPM-G000-15200007, Sec-9.1

SAEP-1160, Section 8 Bullet Item 2 SPM-G000-15200007, Sec-7 & 8

SIS Sheet Data (pressure, limiting factor, medium & temperature) is B2

checked* for accuracy against the test application and is correct. *Note: Human error (test package calcs) is common. Inspectors responsible for testing are able to spot gross errors & prevent unsafe testing & overpressurization of systems & components.

C

C1

SAEP-1160, Section 8 Bullet Item 2

Test Manifold & Appurtanances (Piping, Fittings, Hoses)

Pressure testing manifolds were separately pressure tested to at least

1.2 times system test pressure. (Manifold Test Report/Cert)

Pressure rating or design of test manifold components* (isolation valves, C2 pipe nipples, fittings) exceed system test pressure by 20%. S ee S afety Note 1 in R emarks for i s olation valves

Page 3 of 8

SAES-A-004 Para 5.5.4 / SPM-G000-15200007, Sec-6.4.4 G.I.-2.102, Para. 5.1.5.5


22-Jan-14

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3


SAIC-A-2011

PROJECT TITLE

ITEM No.

C3

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

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) Each test manifold is identified with a unique number (certificate) D) Shows actual arrangement including hose configuration used

G.I.-2.102, Para. 5.1.2.5

Note 1: Manifold permanent marking (unique ID #, pressure rating) is legible, traceable & certified (Engineering support docs).

C4

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 support test manifolds with any necessary calculations (SIS sheet) and the appropriate visual Inspection and any necessary NDE.

G.I.-2.102, Para. 5.1.5.5

Note: Unknown piping schedules can be determined by using a UT Thickness meter. Weld quality is verified by VT or RT.

C5

C6

A blow down valve of adequate pressure rating is installed to

depressurize the system safely (easily accessible to operator).

Test piping 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 maximum system test pressure only if a higher test pressure is impractical.) Paddles or spectacle blinds & other fabricated test items used to

C7

D

isolate test sections are at least the same code class rating of systems under test or are supported by appropriate code calcs. S ee Remark s , Cr itical Safety Note 2

G.I.-2.102, Para. 5.1.5.3 S-PM-G000-15200007 Sec 6.4.2

G.I.-2.102, Section 5.1.5

SAES-A-004 Para. 7.3 / S-PMG000-1520-0007, Sec-8.3.1

Test Relief Valve(s)

G.I.-2.102, Para. 5.5 with Isolation valves on the inlet and outlet of the relief valve sealed open S-PM-G000-15200007 Sec during the test. (SAEP-1160, Bullet Item # 3) 6.4.5 Relief valve is located in the system under test and near the test pump

D1

D2

Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available) are set to relieve at 5%* above the hydrotest pressure. *Note: Test pressures less than 85% of SMYS can have relief valves set at 10% above test pressure. Verify SIS sheets calcs.

D3

Relief valve(s) are tested, dated, and tagged (as valid) for a period of one week for project pressure tests. Stickers are legible & valid.

E

Pressure Gages and Recorders

Page 4 of 8

SAES-A-004 Para 5.5.1 / SPM-G000-15200007, Sec-6.4.1 SAES-A-004 Para 5.5.1 / SPM-G000-15200007, Sec-6.4.1


22-Jan-14

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE


Rev 3


SAIC-A-2011

PROJECT TITLE

ITEM No.

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE


QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE

A minimum of two pressure gages are required for test systems, with accuracy within 5% of one another.

E1

E2

Note 1: When large systems are tested, Inspection personnel will determine the need for additional gages. Note 2: Elevation changes (hydrostatic head considerations) & hot weather create pressure testing problems with 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) month prior to test. Stickers applied indicate latest calibration date.

Test gauge is located at bottom of any equipment/system under test to enable reading test pressures inclusive of hydrostatic head. E3

E4

F

F1

F2

Note: Locate test manifold (with gage) at low points in systems under test. One foot of water (30 cm) @ ambient temperature = pressure increase of .433 psi. (1-meter = 1.42, 10-meter = 14 psi).

All gages have a range such that the test pressure is within 30% to 80% of the full range.

SAES-A-004 Para 7.1.5 / SPM-G000-15200007, Sec-8.1.5

SAES-A-004 Para 7.1.5 / SPM-G000-15200007, Sec-8.1.5 G.I.-2.102, Sec.4 & SAES-A-004, Para 5.3 / S-PMG000-1520-0007, Sec-8.1.5 SAES-A-004 Para 7.1.5 / SPM-G000-15200007, Sec-8.1.5

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). Note: ASME V, Art 10, Man. App. 1, Table 1-1021 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 pressure test where pressure variations due to test water t emperature changes occur, such as in cross-country pipelines.

SAES-A-004 Para 5.6.1 / SPM-G000-15200007, Sec-6.5 SAES-L-150, Para. 11.3 /SPM-G000-13600001-Sec-25.6

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, / S-PM-G000-1520-0007, General Requirements for Pressure Testing, 2. GI-2.102, Company General Instruction-Pressure Testing Safely, 3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, /S-PM-G000-1360-0001-General Specification f or Piping. 4. Pro Forma Contract Schedule Q (Project Specific) 5. SAEP-1160

Page 5 of 8


Rev 3 SAIC NUMBER


ITEM No.

DATE APPROVED

SAIC-A-2011

PROJECT TITLE


ACCEPTANCE CRITERIA

REFERENCE


30-Jun-08 QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE

Company


Company PMT


T&I Witnessed

QC Record Reviewed

T &I W it ne ss ed


T&I Witnessed

QC Record Reviewed

Work Verified


QC Inspector




Work Verified


QC Supervisor





Y = YES

Page 6 of 8

Work Verified

N = NO F = FAILED


Rev 3


SAIC NUMBER

SAIC-A-2011


22-Jan-14

QR NUMBER

MECH-

Attachment 1 - SAEP-1160 Test Pkg Minimum Requirements

Page 7 of 8


Rev 3


SAIC NUMBER

SAIC-A-2011


22-Jan-14

QR NUMBER

MECH-

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. 7.1.3) 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 7.1.4): 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 (Para 7.2): a) Rotating machinery, such as pumps, t urbines 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 water shall be removed from the valve body and seat area. Blow dry with clean compressed air. e) Apply manufacturer approved lubricant plus 10% Cortec VpCI-329 (SAP 1000173887) added to all interior 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.

Page 8 of 8


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Inspection of Filling & Pressurization (Hydrotest)

SAIC-A-2013

PROJECT TITLE


EQUIPMENT ID NUMBER S



REV. NO.




A1

A2

ACCEPTANCE CRITERIA

REFERENCE

General Requirements Pressure Test Procedure is approved and all safety precautions per GI0002.102 & SAES-A-007 (Chemical Handling) have been taken. All in-line valves (if not test isolation) are open*. Note: A fully open valve can leak at stem packing. Items that interfere with filling & Sensitive equipment have been removed from the piping system.

S ys tem tes t limits are chec ked dur ing Ins pection walk dow n

A3

A4

A5

A6

A7

A8

A9

, continuously at a rate that will provide the specified concentration while filling the system for the hydrostatic test. See Attachment 1

E nsure safe filling of sys tems with proper ly propor tioned chemi cal treatments. S ee Attachment 1 for . fluid enters (shall be drained) at the lowest point in the system. All vents are open during filling. Minimize Trapped air. See Attachment 1 (Hydrotest Filling & Venting Practices) Quality Manager &

SAES-A-004, Section 5.6.1 S-PM-G000-15200007 Sec-6.4 SAES-A-004 Para 8.1.3 SPM-G000-1520-0007 Sec-8.1.3

SAES-A-007 Section 8 /SPM-G000-114Z-0003 Sec-10

SAES-A-004 Para 8.1.1 S-PM-G000-1520-0007 Sec-8.1

emove a r ur ng ng y e o ow ng measures: A) Design/Plan Tests. Provide high point vents. B) Mechanically (Use scrapers as needed to remove air). C) Follow Attachment 1 regarding Efficiency Note: Venting may be accomplished by vent valves or blind flanges with properly attached test implements (welded couplings, etc that are located at the hi hest oint in the flan e to minimize After venting, valves used for venting are placed in the partially open position and plugged or blinded as applicable. roce ure requ remen s are o owe s ep y s ep: 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 staged (Adequate* hold time between stages) D) Inspection & Test Crew follow safety responsibilities during test

GI-002.102, Para. 5.15

SAES-A-004 Para 8.1.3 SPM-G000-1520-0007 Sec-8.1.3

GI-002.102, Attachment 1, Section 2

Preliminary check for leaks at 50% of the strength test pressure was performed. Test crews were efficient in filling practices. 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 (tanks). 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 s hould also follow this minimum reqmt. Document the "actual" test temps 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 S ee Attachment 2. problem.

GI-002.102, Para. 5.16

32-SAMSS-004 Para 16.3.10

Page 1 of 4

MECH.

SYSTEM ID.

PLANT NO.



QR NUMBER




A

22-Jan-14

EQPT CODE


ITEM No.


MH's SPENT

TRAVEL TIME


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER


SAIC-A-2013

PROJECT TITLE

ITEM No.


ACCEPTANCE CRITERIA


REFERENCE

QR NUMBER

22-Jan-14

MECH.


PASS

FAIL

N/A

RE-INSP DATE

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. Company General Instruction Manual GI-002.102, Pressure Testing Safely, (28 Ocober 2008) 2. SAES-A-004, S-PM-G000-1520-0007 General Requirements for Pressure Testing 3. SAES-A-007, S-PM-G000-114Z-0003, Hydrostatic Testing Fluids and Lay-Up Procedures, 4. 32-SAMSS-004, Manufacture of Pressure Vessels, (30 March, 2005)

Contractor / Third-Party Construction Representative*

Company Company PMT


T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified


QC Inspector





QC Supervisor





Y = YES

Page 2 of 4

N = NO F = FAILED


Rev 3


SAIC NUMBER

SAIC-A-2013


QR NUMBER

22-Jan-14

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 w ater. 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 = 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 T EST 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 t o 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 crew s 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. 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 ef ficiency. Communication issue (cell, radio, etc)

Page 3 of 4



Rev 3 SAIC NUMBER

SAIC-A-2013


22-Jan-14

QR NUMBER

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 ar e 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 w hen 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 T EST 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. W HERE CLIMBING IS REQUIRED, REQUIRED COORDINATED INSP EFFORTS. PRACTICE IS RECOMMENDED FOR PRESSURE TESTING PROCEDURES & IMMEDIATE IMPLEMENTATION.

Page 4 of 4


Rev 3 SAIC NUMBER


SAIC-A-2013

PROJECT TITLE


ITEM No.

ACCEPTANCE CRITERIA


REFERENCE

QR NUMBER

22-Jan-14

MECH.


PASS

FAIL

N/A

RE-INSP DATE

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. Company General Instruction Manual GI-002.102, Pressure Testing Safely, (28 Ocober 2008) 2. SAES-A-004, S-PM-G000-1520-0007 General Requirements for Pressure Testing 3. SAES-A-007, S-PM-G000-114Z-0003, Hydrostatic Testing Fluids and Lay-Up Procedures, 4. 32-SAMSS-004, Manufacture of Pressure Vessels, (30 March, 2005)


Company


Company PMT


T &I W it ne ss ed


Work Verified

T &I W it ne ss ed


Work Verified

T &I W it ne ss ed


Work Verified


QC Inspector





QC Supervisor





Y = YES

Page 5 of 7

N = NO F = FAILED


Rev 3


SAIC NUMBER

SAIC-A-2013


QR NUMBER

22-Jan-14

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 = 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 cr ews for safety & efficiency. Trapped air is usually adequately displaced when a solid flow or stream of water is observed com ing out of the vent. 8. INSPECTION SHALL EVALUATE EFFICIENCY & ASSURE BEST PRACTICES TO MINI MIZE 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. 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)

Page 6 of 7


Rev 3


SAIC NUMBER

SAIC-A-2013


22-Jan-14

QR NUMBER

MECH.


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 (DET AILS 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 (i dentify 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 T APE 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.

Page 7 of 7


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Visual Inspection at Test Pressure

SAIC NUMBER

PROJECT TITLE


SAIC-A-2015




REV. NO.




A

SYSTEM ID. EC / PMCC / MC

QUANTITY INSP.


ACCEPTANCE CRITERIA

PIPE

CONTRACTOR / SUBCONTRACT



QR NUMBER

22-Jan-14

EQPT CODE


ITEM No.


MH's SPENT WORK

REFERENCE

PASS

FAIL

N/A

General Requirements ... Use SATR-A-2001 with this checklist

A1

After the test pressure is reached and before commencement of inspection of the system, the isolation valve between the temporary test manifold/piping and the piping/equipment under pressure test shall be closed and the test pump disconnected. See Attachments 1 & 2.

SAES-A-004, Para. 8.1.2/ S-PM-G000-15200007 Sec-8. Sec-9.12.

A2

All joints including welded shall be left exposed for visual leak detection during the strength test. External coating & priming of such joints is not allowed unless approved by Company. the Manager of Inspection Department and the proponent Organization representative. The pipe itself can be externally primed and coated to a final coat. See Attachment 3 (Walkdown Inspection Technique).

SAES-L-150, Para. 7.3 / S-PM-G000-13600001, Sec-23.16

A3

The test pressure shall be maintained for a sufficient time, but shall not be less than 30* minutes, to determine that there are no leaks. *Larg e sys tems ( Plant Pi ping ) can take long er to complete.

SAES-L-150, Para. 7.2 / S-PM-G000-13600001, Sec-23.15

A4

Exceptions to Item A3 above, Plant Piping Pressure Testing & Visual Inspection Requirements. See Attachment 4. Visual Inspection & Testing meets SAES-L-150 reqmts.

SAES-L-150, Section 7 Plant Piping / S-PM-G0001360-0001, Sec-23

A5

Exceptions to Item A3 above, Pipeline Pressure Testing & Visual Inspection Requirements. See Attachment 4. Visual Inspection & Testing meets SAES-L-150 reqmts.

SAES-L-150, Section 8 Pipelines

A6

Test procedures, pressures, durations, & leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated isolation valves shall have zero leakage. Valve Testing details are included in separate Procedure

SAES- L-108, Para. 4.7.5 / SPM-G000-1360-0001, Sec. 23

A7

Test Records for each test are entered on a Pressure Test Report Form 2642-ENG. Test duration & Acceptance is shown in Comment section of report. (Tape has test pressure & test start/finish time) Remove tape from gage & press into T est Report. Attachment 2. Test Record shall be made for each test. Form shall be prepared as per S-PMG000-1520-0007, Sec 9.3.

SAES-A-004, Para. 8.3 S-PMG000-1520-0007 Sec-8. Sec 9.3.

REMARKS: ATTACHMENTS: Attachment 1 - Pressure Testing Details --------- Attachment 2 - Efficient Practice For Acceptance of Pressure Tests Attachment 3 - Walkdown Inspection Techniques ----------- Attachment 4 - SAES-L-150 Pressure Testing Application & Insp REFERENCE DOCUMENTS: 1. SAES-A-004,S-PM-G000-1520-0007 General Requirements for Pressure Testing, (30 March, 2005) 2. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (10 May 2007) / S-PM-G000-1360-0001, General Specification for Piping 3. SAES-L-108, Selection of Valves, (21 December 2005)


Company


Company PMT


T&I Witnessed

QC Record Reviewed

T&I Witnessed

QC Record Reviewed

T&I Witnessed

QC Record Reviewed


QC Inspector





QC Supervisor


Name, Or anization,

Page 1 of 8

ame,

gn an

ate:

Initials and Date:


Y = YES

Page 2 of 8

R

PLANT NO. NO. TRAVEL TIME PERMIT REQUIRED?

RE-INSP DATE

Work Verified

Work Verified

Work Verified

Page 3 of 8

N = NO F = FAILED

Page 4 of 8


Rev 3

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Visual Inspection at Test Pressure

SAIC NUMBER

SAIC-A-2015


QR NUMBER

22-Jan-14

PIPE-

Attachment 1 - Pressure Testing Details Plant Piping Pressure Tests with fluids (Strength & Service tests) are staged with inspection as follows: A) Preliminary leak check at 50% of test pressure = com plete visual to check for leaks. (Contractor) B) Twenty per cent stage increase thereaft er = visual inspection for leaks as evidenced by no noticeable pressure drop at test gage. Note Filling & Venting Practices & Ef ficiency C) Final at 100% of test pressure with test pump pump disconnected = Complete visual inspection during full system walkdown for leaks by all Inspectors & Witnesses. (SA Inspector Witnesses & Accepts/Rejects test) See Attachment 2 for 2 for Efficiency related to testing and inspection of small systems. PRESSURE DROPS (GAUGE READINGS) - SURVEILLANCE OF TESTING REPAIR MEETHODS On return to test manifold & taped gage after preliminary walkdowns, any drop (noticeable) in pressure must be accounted for by the Inspector. The test does not proceed to a higher pressure until all leaks are repaired and repaired by approved methods in procedures as f ollows: • Flanged connections can be retorqued to maximum torque value • Valve stem packings are tightened to stop leaks (Caution: ( Caution: Watch Watch for uneven Packing Gland flange adjustment) Note: Often Valves arrive from manufacturer with uneven packing gland flanges. Adjustment/repair may be needed. • Threaded joint leaks are repaired (seal welded or reworked) • Weld joint leaks are repaired (approved welding repair procedure) • Weld joint leaks are repaired (approved welding repair procedure) After repairs, pressurize system & repeat the entire walkdown, never assume all leaks are repaired. SEE ATTACHMENT 3 FOR WALKDOWN T ECHNIQUES DURING FINAL PRESSURE TESTING (ACCEPTANCE)

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 cr ews for safety & eff iciency. Trapped air is usually adequately displaced when a solid flow or stream of water is observed com ing out of the vent. 8. INSPECTION SHALL EVALUATE EFFICIENCY & ASSURE BEST PRACTICES TO MINI MIZE 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. 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)

Page 5 of 8


Rev 3

SAUDI ARAMCO ARAMCO INSPECTION CHECKLIST Visual Inspection at Test Pressure

SAIC NUMBER

SAIC-A-2015


22-Jan-14

QR NUMBER

PIPE-


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 (DET AILS AS AGREED 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 (i dentify 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 T APE AFFIXED INTO TEST REPORT. PACKAGE CONTROL IS CRITICAL FOR EFFICIENCY. LATER, SIGNATURES ARE OBTAINED EASILY 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, 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.

Page 6 of 8


Rev 3


SAIC NUMBER

SAIC-A-2015


QR NUMBER

22-Jan-14

PIPE-

Attachment 3 - Walkdown Inspection Techniques Hot Weather Effect & Test Interpretations (Inspector to Note): 1. Test pressures rise steadily and very noticeably due to rise in pipe surface temps during Summer. 2. Test pressure at gage can remain the same and even rise slightly with very small leaks* * Ensure good walkdown practice. Check valve stems, threads, flanges & low points very closely. Never assume a test result based on the test gauge. Visually examine the entire pressure boundary methodically. 3. Relief valves (set 5% above test pressure) can pop and lower test pressures (nullify test results) *Efficiency is needed to complete exams as quickly as possible without rushing through inspection. 4. In hot weather, ensure careful bleedoff in inspection presence. Maintain minimum test pressure. 5. Always account for noticeable drops in test pressures. See Potential Leak Sources.

Potential Leak Sources (Inspector to Note): a) Valve leakby and test connection threaded fitting leaks (worn) are the # 1 cause of failed tests*. * Closed valves used as a test lim it are never assumed t o be "passing" water. Verify no other leaks * Closed valves in the test m anifold are checked and replaced if they "pass", verify no other leaks * Threaded pressure hose connections wear out & need frequent replacement. Most common leak. b) Valve packing leaks are very often found with NO* noticeable test pressure dr op (in hot weather) *The normal test pressure rise due to sun-heated piping is not seen, but negated by packing leak. c) Flanges with small leaks are hard to find. Check low points by hand*patting & use mirror/light. *A sheet of dry paper can be patted against lowest periphery of the flange. Watch for sharp edges! d) Threaded joints* are checked closely (leaks are common with inadequate thread engagement). *Seal welded threaded joints often leak. Best t echnique is close visual checks with mirr or & hand. e) Socket welds (GTAW & SMAW process) can leak through tiny pores caused by oil contamination. f) Butt weld leaks are rare & 100% through-wall porosity is often the culprit. g) Telltale hole leakage (stanchion legs, dummy legs, repads) is thru attachment welds* * Attachment welds to pressure boundary can burn through & create thru-wall defects that leak h) Pipe/Fitting manufacturing defects cause thru-wall leaks. There is a variety of common defects* * Seams, laps, slugs, delaminations, pinholes, tears, shuts and thread defects (torn, flat, etc) 6. Leakage Evidence or questionable leakage (also check gage pressur e) is always investigated

Investigate Leakage Evidence (Inspector to Note): 1) Visually attempt to determine the exact source* of leakage evidence (except for obvious leaks) * Never Assume Leakage Evidence is local. T he source may be another line (Know the Effects of Gravity). * Never Assume water present means a test system leak. (Filling Leak Repaired, another source) * Assess leakage evidence carefully by a detailed visual inspection/observation method: * Check test gage or have a test crew member return & check the gage for obvious pressure drop * Never assume because pressure hasn't dropped that a leak does not exist (hot weather effect) 2) Approach the area with caution. Assess the evidence. Is the leak ACTI VE? (Obviously wet or dripping) 3) If yes, wipe the area dry & wait a few seconds (on further leaks, mark the location & move on) 4) If not obvious, but a leak is suspected, wipe area dry & wait 60* seconds. Use Hand/dry paper! * Ascertain a leakage rate (in drops/minute). Move on and complete the remainder of test. PROBLEM 5) Test crews often struggle with small leaks & use a pressure gage as their acceptance criteria*. REASON = INSPECTOR IS LIKELY ACCEPTING TESTS BASED ON GAUGE RESULTS ALONE SOLUTION = AWARENESS 6) Any Leakage found (rate) on unsuccessful tests is entered in Test Report "Remarks/Comment" Section Example: Retest OK (no leaks at test pressure) after minor valve packing leaks (2 drops/minute) repaired

NEVER ASS/U/ME A TEST RESULT BASED ON THE TEST GAUGE ALONE Page 7 of 8



Rev 3 SAIC NUMBER


SAIC-A-2015

QR NUMBER

22-Jan-14

PIPE-

Attachment 4 - SAES-L-150 Pressure Testing Application & Insp 7 Plant Piping Applications 7.1 Unless limited by flanges, valves or ot her component in the line or specified in paragraph 7.4 below, the hydrostatic strength test pressure for every section of new constructed line shall produce a hoop str ess in the pipe of 90% of the specified minimum yield strength (SMYS) at the test temperature. 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. 7.2 Except where specified in 7.4 of this standard, the test pressure shall be maintained for a sufficient time, but shall not be less than 30 minutes, to determine that there are no leaks. (Item A3 of this Checklist) 7.3 All joints including welded shall be left exposed for visual leak detection during st rength test. External coating and priming of such joints are not allowed unless approved by Manager of Inspection Departm ent and the proponent\ Organization representative. The pipe itself can be exter nally primed and coated to a final coat. 7.4 Following are specific cases of exemptions to either or both of 7.1 and 7.2 of this standard (Item A4): 7.4.1 Lube and seal oil piping shall be pressure tested with its own fluid. The test pressure shall be 1.5 times the design pressure or 690 kPa (ga) (100 psig) whichever is the greater. Test duration shall be in accordance with 7.2. 7.4.2 Underground process piping shall be tested prior to backfilling. The test pressure shall be maintained for a minimum of 2 hours while the joints are inspected for leakage. If for justifiable safety reasons the line must be backfilled, then the joints shall remain exposed during testing, otherwise the test shall be a 24 hour recorded test. The test pressure is in accordance with 7.1. 7.4.3 Flare lines 24-inch NPS and larger* with a design pressure of 517 kPa (ga) (75 psig) or lower may be pneumatically strength tested in accordance with paragraph 345.5 of ASME B31.3. * Note: Portions of this line may be smaller than 24" and extend to isolation valves downstream of PZVs, etc 7.4.4 Piping in vacuum service shall be pressure tested to 1.5 times the differential external pressure not less than 100 kPa (ga) (15 psig). Test duration shall be in accordance with 7.2.

7.4.5 Service test is acceptable for the following per L-150, Para. 7.4.5 (Threaded Joints) a) Plant utility piping in air & inert gas services with designed pressure & equal to less than 035 kPa (ga) (150 psig). b) Low pressure steam piping designed for 60 psig or less. INSPECTION SHALL REFER TO SAIC-L-2015 CHECKLIST FOR THREADED JOINTS AS APPLICABLE. 7.5 For revalidation purposes of existing plant piping, test pressure shall be minimum req'd by ASME B31.3. Actual piping wall thickness and flange rating shall be taken into consideration when calculating the test pressure.

8 Pressure Testing of Pipelines This section defines specific requirements (such as test pressure, duration, etc.) for pressure testing of pipelines. 8.1 Unless limited by flanges or valves in the line, hydrostatic strength test pressure for every section of newly constructed pipelines shall be calculated to produce a hoop st ress of 90% of the SMYS of the pipe mat erial based on the nominal wall thickness. The test pressure at the lowest point of the pipeline, considering hydrostatic head, shall not result in a hoop stress greater than the SMYS. Strength test pressure shall be maintained for 2 hours. 8.2 The strength test temperature shall not result in a combined longitudinal stress (calculated based on 0.7 hoop stress at the test pressure plus temperature stress plus bending stress) exceeding the SMYS. 8.3 Tightness test shall be conducted at 95% of strength test pressure, immediately after completing strength test. Tightness test pressure shall be maintained as long as req'd for inspector to examine all exposed joints. A 24-hour recorded tightness test shall be applied when the pipeline is buried or insulated, or is partially buried or insulated for more than 300 m (1000 ft) or 10% of its total length whichever is less. 8.4 Existing pipelines if subjected to revalidation pressure testing, the test pressure shall be minimum of 1.25 times the MAOP for pipelines with 0.6 and 0.72 design factors; and shall be minimum of 1.4 times the MAOP for pipelines with 0.4 and 0.5 design factors. The actual pipe wall thickness and flange r ating shall be taken into consideration when calculating the test pressure. For Pipelines, The results of the latest (new) pressure testing shall be documented in the "Safety Instruction Sheet".

PIPELINE PRESSURE VARIATIONS (TEMPERATURE VARIATIONS) 11.3 Where pressure variations due to test water temperature changes occur, such as in cross-country pipelines, thermocouples shall be installed to obtain accurate pipe metal temperature measurements to determine the acceptance of the pressure test. Chairman of the Piping Standards Committee in Consulting Services Department shall be consulted for any deviations on the 24 hour pr essure chart. Page 8 of 8


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Visual Insp of Air Test on Repads & Weld-Plus-Ends Cplgs PROJECT TITLE



22-Jan-14

QR NUMBER

MECH-


202319 EQUIPMENT ID NUMBER(S)



REV. NO.


EQPT CODE


ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER



A

A1

ACCEPTANCE CRITERIA

REFERENCE

Weld-Plus-Plus Ends Weld-Plus-Ends shall be subjected to pneumatic pressure test of 35 to 70 kPa (ga) (5 to 10 psig) in the annulus between the gasket and seal weld. It shall be examined for leaks using a soap solution.

*Refer to SA IC-A -2023 for B ubble Leak Test (A SME V).

Page 1 of 2

SAES-L-150, Para 10.2 / SPM-G000-13600001, Sec-25

PLANT NO.



ITEM No.

SYSTEM ID.

MH's SPENT

TRAVEL TIME


PASS

FAIL

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Visual Insp of Air Test on Repads & Weld-Plus-Ends Cplgs PROJECT TITLE


ITEM No.

ACCEPTANCE CRITERIA


REFERENCE

QR NUMBER

22-Jan-14

MECH-


PASS

FAIL

N/A

RE-INSP DATE

REMARKS: REFERENCE DOCUMENTS:

3. SAES-L-150 Pressure Testing of Plant Piping and Pipelines, / S-PM-G000-1360-0001, General Specification for Piping


Company


Company PMT


T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed


W or k Ve ri fi ed

T &I W it ne ss ed


Work Verified


QC Inspector





QC Supervisor





Y = YES

Page 2 of 2

N = NO F = FAILED


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Depressurization & Disposal of Hydrotest Water

SAIC-A-2017

PROJECT TITLE





REV. NO.




22-Jan-14

QR NUMBER

MECH.


EQPT CODE

SYSTEM ID.


PLANT NO.


MH's SPENT

TRAVEL TIME





ITEM No. A

A1

A2

ACCEPTANCE CRITERIA

REFERENCE

General Requirements Depressurization is done slowly and safely after completion of test or on discovery of leaks. Bleed off the system slowly to an approved safe discharge area and monitor discharge. Inspection ensures written procedures approved prior to testing are followed upon disposal of any test medium containing chemical additives for control of corrosion and bacteria.

GI-002.102, Section 5.2.6

GI-002.102, Section 5.2.7

Dis posal methods follow S AE P-327, S ection 3 requirements . B

Specific Disposal Requirements

B1

New pipelines, and pipelines in gas service do not require oil/water separation prior to wastewater discharge/disposal.

SAEP-327, Section 3.2.1 /SPM-G000-15200007 Sec-10.2

B2

Do not discharge wastewater to local wadi environments. Discharge separated wastewater to non-sabkhah areas into approved pits or to lined evaporation ponds constructed.


B3

As far as possible locate the disposal site within the existing pipeline corridor while ensuring adequate pipeline access and without causing damage to the existing roadways, pipelines, private entities or other structures


B4

Do not dispose wastewater within or adjacent to wetland or sensitive environments, including specified conservation areas


B5

Disposal to Sabkhah Discharge separated wastewater directly to the sabkhah for evaporation provided that the wastewater remains on land, and does not flow directly to the marine environment. An oil/water Separator Pond is required before wastewater is discharged to sabkhah to ensure retention of residual hydrocarbon for subsequent collection and proper handling. Separator pond site is downwind to minimize exposure risk to nearby facilities personnel.

SAEP-327, Section 3.3 /SPM-G000-15200007 Sec-10.2

B6

Disposal to an Evaporation Pond Oil/water separator ponds are required upstream of evaporation ponds to collect residual hydrocarbon and improve evaporation in the evaporation ponds.


B7

Disposal to Industrial Wastewater Treatment Plant Discharge wastewater directly to the local industrial wastewater treatment plant if disposal does not affect the normal operations of the plant. Obtain concurrence from the operators of the treatment plant prior to selection of this disposal option.


Page 1 of 3


PASS

FAIL

N/A

RE-INSP DATE

B8

Disposal to Injection Well Dispose wastewater into injection wells if it does not affect the well operation. Obtain concurrence from the operators of the well prior to selection of this disposal option. Injection well operators will provide water quality criteria for any wastewater that will be introduced to their system for disposal

Page 2 of 3



Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Depressurization & Disposal of Hydrotest Water

B9

B10

DATE AP PRO VE D

SAIC-A-2017

PROJECT TITLE

ITEM No.

30-Jun-08

SAIC NUMBER

22-Jan-14


ACCEPTANCE CRITERIA

QR NUM BER

MECH.


REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Disposal Offshore Dispose wastewater offshore to the Arabian Gulf or Red Sea per SAEP- SAEP-327, Section 3.7 /SPM-G000-1520-0007 Sec327 Table 1 (See Excel Sh # 2 Att'd). Adequate dispersal of 10.2 wastewater in marine environment by diffuser or similar method or transfer wastewater onshore for treatment/disposal. Biocides other than Troskil-1 (Polyhexamethylene biguanide hydrochloride or PHMB) require evaluation & approval by EPD/EED prior to disposal to the Arabian Gulf or the Red Sea.

Water D is posal Approval Form has been submitted

SAEP-327, Section 3.7.1 /S-PM-G000-1520-0007 Sec-10.2

B11

Dispose wastewater with Rhodamine B and TROS (fluorescent) dyes into deep water, shallow water and embayment systems per SAEP-327 Table 1 (See Excel Sh # 2 Attached). For other dyes provide toxicity data, submit Water Disposal Approval Form. Notify Frontier Force of any discharges of dyes to sea to prevent alarm.


B12

Use a spray nozzle to allow maximum oxygenation of discharge of waters containing oxygen scavenger added


B13

Submit Water Disposal Approval Form and obtain approval from EPD/EED before discharge of any wastewater to embayments and/or conservation areas in the Arabian Gulf


Discharge of c ontaminated wastewaters follows SAES-A-103. A) Discharge locations are where water columns are deepest. B) Discharge there is as close to the water surface as practicable. B14 C) If only oxygen scavenger is used, discharge is into the air and discharge rate is less than five cubic meters per minute D) Alternatively, SAES-A-104 allows injection of wastewater into any petroleum reservoir producing hydrocarbons.


B15

Submit Water Disposal Approval Form and obtain approval from EPD/EED before disposal of wastewater to the Red Sea


B16

For pipelines, dewatering is performed by scraping. If sea water was used for testing a pipeline, remove salt deposits by scraping with slugs of water containing less than 4500 mg/L total dissolved solids until the water soluble sulfates and chlorides on the steel surface at the drain or outlet end are reduced to <80 mg/m².

SAES-A-007 Para 5.2.3.3 /S-PM-G000-114Z-0003 Sec-7.2.5.2

REMARKS: REFERENCE DOCUMENTS: 1. SAES-A-007, /S-PM-G000-114Z-0003, Hydrostatic Testing Fluids and Lay-Up Procedures, (3 July 2007) 2.

SAEP-327, /S-PM-G000-1520-0007, Disposal of Wastewater from Cleaning, Flushing, and Dewatering Pipelines and Vessels.

3.

Company IGeneral Instruction Manual GI-002.102 (28 October 2008) Pressure Testing Safely

Contractor / Third-Party Construction Representative*

Company Company PMT


T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified


QC Inspector





QC Supervisor





Y = YES

Page 3 of 3

N = NO F = FAILED


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Lay-up of Piping Systems & Vessels

SAIC-A-2018

PROJECT TITLE

22-Jan-14





REV. NO.




ACCEPTANCE CRITERIA

REFERENCE

MH's SPENT

TRAVEL TIME


PASS

A

General Requirements ... USE SATR-A-2009 & SATR-A-2014 with this checklist for Lay-Up

A1

Lay-Up Procedure or Method Statement is project specific and identified in Project Quality Plan. (SPECIAL CONSTR. PROCESS).

Note Sig nificant changes to SAE S-A -007 (Oct 2005 Revis ion)

PLANT NO.



MECH-

SYSTEM ID.



QR NUMBE R


EQPT CODE


ITEM No.

30-Jun-08 DATE APP ROV ED

FAIL

N/A

RE-INSP DATE

Sch Q, Project Specific

A2

Procedure covers SAES-A-007 General Reqmts regarding: A) Water Quality B) Planning & System Design for Lay Up See Attachment 1

SAES-A-007, Section 4.1 /SPM-G000-114Z0003 Sec-6

A3

Procedure has been reviewed & approved by Saudi Aramco

Sch Q, Project Specific

B

CARBON STEEL & LOW ALLOY (P-No. 3/4/5) PRESSURE PIPING SYSTEM LAY-UP (See Section C for Specific Applications)

B1

Treatment of Hydrostatic Test Water: When the CS equipment contact time with hydrotest water may exceed 14 days (14-day rule), approved oxygen scavenger (App. 1) shall be SAES-A-007, added to the hydrostatic test water. Treat water before it enters the Para. 5.1 /S-PMsystem. Use batching scrapers and/or a slug of nitrogen to separate the G000-114Z-0003 air in the system from coming in contact with treated water, then fill Sec-7.1 systems with water injecting sufficient oxygen scavenger to maintain its residual concentration at greater than 20 ppm & an oxygen concentration of less than 10 ppb.

B2

Lay-up Plan meets/addresses/details the following requirements: A) Equipment must be laid-up after hydrotesting unless it can be ensured that it will be returned to service within 30 days from the first introduction of hydrotest water to the system. SAES-A-007, B) One of the lay-up methods in Item B3 shall then be selected. Para. 5.2.1 /SC) Section C of this checklist (Specific system & equipment reqmts) PM-G000-114ZD) Lay-up procedures for pipelines under the responsibility of 0003 Sec-7.2.1 Pipelines Dept shall be approved prior to hydrotest by the General Supervisor, Pipelines Technical Services Division (PTSD), & by the Mgr of the concerned area. Approval of lay-up procedure for other equipment shall be the responsibility of SA Eng Suptd. or designate.

B3

Lay-up is one of the approved methods: A) Wet Lay-up (Attachment 2) B) Dry Lay-up (Attachment 3) C) Inert Gas Lay-up (Attachment 4) D) Ambient Lay-up (Attachment 4) E) Other Approved Lay-up Methods (Attachment 4)

SAES-A-007, Para. 5.2.1 /SPM-G000-114Z0003 Sec-7.2.1

B4

Step by step for implementation of Lay-up method exists: A) Verify the appropriate steps cover specific lay-up procedure in attachments 2, 3, & 4 and refer to SAIC-A-2018 (Application). B) SAIC-A-2018 & SATR-A-2009 may be used as a supplementary Layup Procedure.

SAES-A-007, Sec. 5.2.1 /SPM-G000-114Z0003 Sec-7.2.1

B5

At end of lay-up, commission & start up heat exchangers shall be within 14 days, & other equipment within 60 days. This statement is included in Procedure for Carbon Steel Equip.

SAES-A-007, Para. 5.3 /S-PMG000-114Z-0003 Sec-7.3

Page 1 of 12


Rev 3


SAIC NUMBER

LAY-UP OF PIPING SYSTEMS & VESSELS

SAIC-A-2018

PROJECT TITLE

ITEM No.


ACCEPTANCE CRITERIA

REFERENCE

C

SPECIFIC & SPECIAL LAY-UP REQUIREMENTS (Specific Applications)

C1

Tank requirements are as follows (in procedures): Carbon steel open-roof, floating-roof, or API atmospheric cone roof tanks not designed for service above atmospheric pressure, do not require treatment of hydrostatic water. Immediately after completion of the hydrostatic test, drain and remove all traces of visible water. Cleaning shall consider any coating operations.

C2


22-Jan-14

QR NUMBER

MECH-


PASS

FAIL

N/A

RE-INSP DATE

SAES-A-007, Para 7.1 /S-PMG000-114Z-0003 Sec-9.1

Utility System requirements are as follows (in procedures): A) Utility and potable water systems shall be tested in accordance with SAES-S-060 or SAES-S-070, as appropriate. B) Potable water systems shall be tested with fresh potable water only following the requirements of SAES-S-070, Para 18.2. Oxygen SAES-A-007, scavengers and biocides shall not be used i n potable systems. Para 7.2 /S-PMC) For potable water systems, use Dry lay-up per Para. 5.2.3, Inert gas G000-114Z-0003 lay-up using nitrogen per Para. 5.2.4, or Ambient lay-up per Para. 5.2.5. Sec-9.2 See Attachments 3 & 4. D) For Dry-up (moisture removal), sweet gas shall not be used. Methanol or other dehydrating chemicals shall not be used. Procedure details dry-up methods used & means of verification Dry Gas & Refined Hydrocarbon Product Pipelines & Piping. See Attachment 5.

SAES-A-007, Section 7.3 /SPM-G000-114Z0003 Sec-9.3

Sour Gas & Sour Oil Pipelines. See Attachment 5.


C5

PLANT SYSTEMS (PIPING & EQUIPMENT) SHALL BE LAYED UP PER ATTACHMENT 6. Inspectors are familiar with these reqmts.


D

STAINLESS STEEL PRESSURE PIPING SYSTEM & EQUIPMENT (P-No. 6 & above) LAY-UP (INCLUDING NEW VALVE REQMTS)

D1

Type 300-series stainless steel systems* shall be tested only with water having maximum allowable chloride concentration of 50 ppm. Quality of water shall be per Attachment 1. Para. 4.2 in entirety.

C3

C4

CS sys tem with 300 Series S S trim valve is not a SS " sys tem". WATER QUALITY IS TES TED & CE RTIFIE D (SATR-A-2014)

D2

D3

SAES-A-007, Para. 6.1 /S-PMG000-114Z-0003 Sec-8

Type-400-series stainless steels are highly prone to atmospheric corrosion. This includes valves with trim designated 13Cr*. SAES-A-007, *Note: Trims # 1, 4, 6, 7, 8, and 8A are affected by new rule. Para. 6.2 & /SCorrosion Controls shall be implemented in procedures as follows: PM-G000-114Z A) Type 400-series stainless steel trimmed valves shall be removed from 0003 Sec-8 pipelines before hydrotest. (In-line spools are used for testing) SAES-L-105 B) Option B: If it impossible to remove such valves from the line, then Valve Trim written hydrotest procedures must be prepared and approved ahead of Table /S-PMtime allowing the valves to remain in place. G000-1360-0004 See Attachment 7 (Special Notes for 13Cr Trim Valves) Quality Managers & Inspectors are aware of the new reqmt When equipment containing any Type-400 series stainless steels is left in place (Option B above), it shall be hydrotested per reqmts of Paragraph 6.3, 6.4, and 6.5 of SAES-A-007. See Attachment 7.

Page 2 of 12

SAES-A-007, Para. 6.2 & /SPM-G000-114Z0003 Sec-8


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST LAY-UP OF PIPING SYSTEMS & VESSELS

SAIC-A-2018

PROJECT TITLE

ACCEPTANCE CRITERIA

MECH-


REFERENCE

Hydrotest procedure shall carefully detail measures to prevent corrosion including lay-up of the equipment. See Attachment 7. Do not use ambient lay-up for equipment of 400-series SS.

QR NUMBER

22-Jan-14


ITEM No.

D4


PASS

FAIL

N/A

RE-INSP DATE

SAES-A-007, Para. 6.2 /S-PMG000-114Z-0003 Sec-8

REMARKS:

NOTES: 1. Utilize SATR-A-2009 and SATR-A-2014 in conjunction w ith this checklist. . - -

-

-

-

-

-

ATTACHMENTS: Attachment 1 - SAES-A-007 (3 July 07) GENERAL SYSTEM REQMTS Attachment 2 - LAY-UP FOR CARBON STEEL SYSTEMS (WET METHOD) Attachment 3 - LAY-UP FOR CARBON STEEL SYSTEMS (DRY METHOD) Attachment 4 - LAY-UP FOR CARBON STEEL SYSTEMS (INERT GAS, AMBIENT & OTHER METHODS) Attachment 5 - SPECIAL LAY UP PROCEDURES (Dry Gas & Refined Hydrocarbon Product Pipelines & Piping, Sour Gas & Sour Oil Pipelines) Attachment 6 - SPECIAL LAY UP PROCEDURES (Plant Applications, Piping Systems & Equipment) Attachment 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT) Attachment 8 - SAES-A-007 Appendix 1, Approved Oxygen Scavengers REFERENCE DOCUMENTS: 1. Schedule Q Project Specific 2. SAES-L-105 Piping Material Specifications / S-PM-G000-1360-0001, General Specification for Piping 2. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (3 July 2007)


Company


Company PMT


T&I Witnessed


W or k Ve ri fi ed

T&I Witnessed

QC Record Reviewed

W ork Verified

T&I Witnessed

QC Record Reviewed

W ork Verified


QC Inspector





QC Supervisor





Y = YES

Page 3 of 12

N = NO F = FAILED


Rev 3


SAIC NUMBER

SAIC-A-2018


22-Jan-14

QR NUMBER

MECH-

Attachment 1 - SAES-A-007 (Oct 2005 Rev) GENERAL SYSTEM REQMTS Responsibility 4.1 In the case of new construction, the construction agency shall be responsible for adhering to this specification; Projects Inspection shall be the monitoring authority. For existing facilities, the facility proponent Maintenance and Operations shall be responsible for adhering to this specification; the proponent's Operations Inspection organization is the monitoring authority.

4.2 Water Quality 4.2.1 Water quality of intended hydrostatic test waters shall be determined well ahead of actual testing dates so that alternative water sources may be identified if original source water fails to meet reqmts. 4.2.2 Water quality of hydrostatic test waters shall be reconfirmed by testing as close to the time of the hydrostatic test as practicable. In cases where individual tanker trucks are used to supply a test, the water samples shall be drawn from a representative number of actual truck loads being delivered to test sites. 4.2.3 Water used for any part of the hydrotesting or subsequent lay-up shall have a sulfate reducing bacteria (SRB) count of 103 per ml or less as determined by the RapidChek II Method or alternative test method approved by Supervisor, CTU/ME&CCD/CSD. Water that has a higher bacteria count may be accepted at the discretion of the Supervisor, CTU/ME&CCD/CSD, after treatment with biocide & retesting. 4.2.4 If water from more than one source will be used, ensure that mixing waters will not cause scaling. 4.2.5 Water used for any part of the hydrotesting or subsequent lay-up shall be clean and free from suspended matter. Suspended matter in the water shall be extracted, before use, by a filter capable of removing 99% of all particles 53µm (2.1 mil) in diameter and larger, or equivalent to using 270 mesh wire mesh screen. 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 Prev Dept, Dhahran. Exception: Paragraph 5.2.2.1 describes controlled circum stances where water treated with a biocide m ay be used for the hydrotest itself. 4.2.7 Water may be reused for hydrotesting, as in a pipeline tested segment by segment. The water must meet the requirements of Paragraph 4.2.3 and must have an oxygen level of less than 20 ppb, or additional chemical treatment will be required. SS Piping (Exception to 50 ppm Chloride rule): In special cases, with prior written approval of CSD, water of up to 250 mg/liter chloride ion is permitted, provided: a) that hydrostatic test period is less than 4 days & b) system is rinsed with steam condensate or demin water until the effluent chloride content reaches below 50 mg/liter, and (c) that the system is completely drained immediately after hydrostatic test and rinse.

Lay Up Planning & Design 4.3 Minimize the time between introducing hydrostatic test water and commissioning the equipment. 4.3.1 Schedule the hydrostatic test as close as possible to the start-up date. 4.3.2 Where there are limitations in this standard on contact time for hydrotest water, this shall be from first introduction of water into system until commissioning or until implementation of a complete lay-up. Partial or complete refilling of the system shall count as continuous, cumulative time. Time limitations requiring the initiation of a formal lay-up program shall be from the first introduction of hydrotest water. 4.4 Design the hydrostatic test and the lay-up procedure to protect the most corrosion-susceptible material in the system. THE END

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Attachment 2 - LAY-UP FOR CARBON STEEL SYSTEMS Wet Lay-up (See Attachment 8, Oxygen Scavenger Appendix) 5.2.2.1 Wet lay-up shall be achieved whenever possible by displacing the hydrotest water from the line after hydrotest and replacing with appropriately treated lay-up water. This minimizes the personnel safety and environmental risks of hydrotest ruptures releasing biocide-treated waters. In cases where this is not possible, wet lay-up will require the use of water adequately treated with oxygen scavenger and biocide at the beginning of the hydrotest and will require safety and environmental reviews of the procedure. 5.2.2.2 For wet lay-up, establish and maintain throughout the system a minimum residual oxygen scavenger concentration of 20 ppm in the water and a maximum oxygen concentration of 10 ppb. This includes dead legs. Analyze water sample(s) for residual levels of oxygen scavenger and the dissolved oxygen concentration at the location most remote from the oxygen scavenger inlet. Record the test results in the hydrostatic test report. Once minimum residuals are verified, keep systems tightly closed to prevent air entry. Repeat tests and ensure chemical residuals every six months during lay-up unless the physical location of the line or equipment makes this impossible. If a leak occurs or air enters the system, lay-up the system again after completing repairs. 5.2.2.3 Maintain the system under a positive pressure between 210 to 350 kPa (30 to 50 psig) using nitrogen, a sweet hydrocarbon gas, or hydraulic pressure of the treated water. In cases where the design pressure is lower than 350 kPa (50 psig), the pressures shall be adjusted accordingly. Install thermal relief for systems that are to be laid up with hydraulic pressure. 5.2.2.4 Use gauges with a scale range not exceeding three times the target pressure to monitor the positive pressure in the system during lay-up. The gauges must be capable of withstanding the design maximum allowable operating pressure (MAOP) of the system to which they are connected or must be protected with adequate gauge saver devices if they are not capable of withstanding system MAOP. 5.2.2.5 When the total equipment contact time with water may exceed 30 days, microbiological growth shall be controlled by one of the following methods. 5.2.2.5.1 Use a proprietary combined biocide, corrosion inhibit or & oxygen scavenger at a concentration in the range of 350 – 500 ppm. The disposal plan for this treatment must be approved following SAEP-327. When using a combined product that contains oxygen scavenger, the oxygen scavenger component of the product will be considered sufficient to meet the requirements for oxygen control. 5.2.2.5.2 Use a combined biocide and corrosion inhibitor at a concentration in the range of 150 – 200 ppm. The disposal plan for this treatment must be approved following SAEP-327. Commentary Note: Champion Bactron KK-27 is an example of this type of chemical. 5.2.2.5.3 For discharge to environmentally sensitiv e locations, use THPS ( Tetrakis hydroxymethyl phoshonium sulfate) which degrades to non-toxic components. 70% pure THPS shall be applied at 50 ppm THPS is also available as blends with other products which may be less environmentally friendly. The disposal plan for this treatment must be approved following SAEP-327. 5.2.2.5.4 Polyhexamethylene biguanide hydrochloride or PHMB) (SAP Material # 1000178704), may also be used in hydrotests at 200 ppm. The disposal plan for this treatment must be approved following SAEP-327. Commentary Note: ATROS TK-1, Troskil-1, is an example of this type of chemistry. 5.2.2.5.5 Other biocides may be used if approved by the Supervisor, Petroleum Microbiology Unit, Material Sciences R&D Division, R&DC and if approved by Environmental Engineering Division, Environmental Protection Department, per SAEP-327. Ensure that the biocide does not react with oxygen scavenger before using. In cases of doubt, contact Supervisor, Corrosion Technology Unit, Materials Engineering & Corrosion Control, CSD. THE END

Page 5 of 12


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SAIC-A-2018


22-Jan-14

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MECH-

Attachment 3 - LAY-UP FOR CARBON STEEL SYSTEMS Dry Lay-up 5.2.3.1 Dry lay-up may be achieved using several different drying media. These include hot dry air, controlled dew point inert gas, and drying chemicals such as glycol or methanol applied between two pipeline scrapers or as a gelled scraper. The best results may be achieved by using a combination of these techniques. Safety Note: See Paragraph 10 on safety issues. 5.2.3.1.1 Dry lay-up using hot or dew point controlled air may only be used for systems where the dew point can be successfully reached within 1 week. Longer drying periods using air may contribute to the generation of excessive quantities of corrosion products in lines. Therefore, dry lay-up using air is only appropriate for systems that can be easily dried. One means to assure effective drying within req'd times is to limit lengths of systems being hydrotested. 5.2.3.1.2 Sweet gas may be used for dehydration. However, before using sweet gas e nsure that hydrate formation will not be a problem. Hydrate formation may occur at low temperatures & elevated pressures. 5.2.3.2 Remove the hydrotest water from the system. For facilities other than pipelines, drain the system completely, sweep & mop as required to ensure that no visible traces of water remain. For pipelines, dewatering shall be performed by scraping with a three or four cup displacement scraper or better system such as a gelled scraper. Scrapers shall be driven by nitrogen or sweet gas unless the use of dry air has been preapproved. 5.2.3.3 When seawater or similar high salinity water has been used as the hydrotest media, remove salts from the metal surface by rinsing with a low-salinity water containing less than 4,500 ppm total dissolved solids. For pipelines, use a slug of low salinity water between two scrapers to rinse salts from the walls. Size of t he slug will be dependent upon the length of the line. More than two scrapers may be required in cases where a large slug of water is required. Present calculations and assumptions made to justify size of slug to be used. The use of seawater/high salt hydrotest water in fa cilities under the responsibility of Pipelines Department must be pre-approved in writing by Pipelines Dept, General Supervisor, PTSD, and the responsible area Manager. For equipment that is under the responsibility of other Departments, the use of seawater/high salinity water must be pre-approved in w riting by the local corrosion engineer. All mitigation actions shall be presented for approval at design stage prior to commencement of construction or it will not be a permissible option once construction has commenced. ACTION REQUIRED (TYPICAL) 5.2.3.4 If using inert gas drying for a pipeline, first, remove remaining water with methanol or glycol slug between two scrapers, in order to achieve drying in a short period. Then dry with dehydrated inert gas. Gelled chemicals may be used. Ensure compatibility of dehydrating chemicals with all material in system. 5.2.3.5 If at all possible, hydrotests should be performed with the valves removed from the line. However, if this is not possible, valves must be carefully dewatered. As the final stage of dewa tering process, remove water from pipeline valves and all other valves that may be damaged by trapped hydrotest water by blowing through the top drain with nitrogen and displacing fluid out of the bottom of the valve. Do not open or close valve during this dewatering sequence. When the bulk of the w ater has been removed, blow vapor phase corrosion inhibitor Cortec VpCI 309 or equivalent with nitrogen until it is visibly discharged at the bottom of the valve. 5.2.3.6 Immediately after dewatering, start drying system to a dew point that will ensure a dew point of of -1°C or less at the final lay-up pressure at all exit points. Dry by blowing sweet gas, nitrogen, or, if pre-approved, heated dry air through the system for not less than 12 hours to allow any remaining moisture to come to equilibrium with the dry air. Check and ensure that all measurement locations are at or below the required dew point. Repeat the drying procedure if the measured dew point at any one location is above the set limit. For pipelines, dew point readings must be done at the beginning, end, & all mainline valve locations. Record dew point temperature readings at each test location. Record the pressure of the line or system at the time of the dew point measurement. Record pressure at which the dew point measurement is made if different to the actual system or line pressure. If the dew point temperature is derived at a different pressure to lay-up pressure, use App. 2 or equivalent conversion charts to yield dew point at lay-up pressure. Safety: See Para 10.5.1 on separation of air & gas mixtures.See Para 10.5.2 on safety issues concerning nitrogen. 5.2.3.7 When required dew point is reached, pressurize the system with nitrogen or sweet gas to final lay-up pressure. Dry air may be used only if it has been pre-approved. Systems shall be maintained at a positive pressure of at least 30 psig unless this exceeds the design pressure of the system. Pressures up to the normal operating pressure have been used for lay-up for some systems. The dew point at the final lay-up pressure must be lower than -1°C. 5.2.3.8 Shut in the system, maintain and monitor the pressure per 5.2.2.4 during the lay-up period. 5.2.3.9 For pipelines, re-measure dew point at all original test locations one week after reaching final lay-up pressure. If any dew point reading is found to be higher than -1ºC at the lay-up pressure, then the entire line must be dried again or an alternative preservation method must be implemented. THE END (DRY LAY-UP)

Page 6 of 12


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Attachment 4 - LAY-UP FOR CARBON STEEL SYSTEMS INERT GAS LAY-UP 5.2.4.1 Displace the hydrostatic test water by positive pressure with nitrogen or sweet gas until no water drains out of the system. Shut in the system under positive pressure until commissioning and start-up. Ensure that systems being drained have vacuum relief valves and pressure relief v alves as necessary to protect the system. 5.2.4.2 For pipelines, displace water by scraping with a three or four cup displacement scraper or better system such as a gelled scraper. 5.2.4.3 Microbial control per paragraph 5.2.2.5 is not required even though some residual water is left in the system.

AMBIENT LAY-UP (SEE ATTACHMENT 7, SPECIAL VALVE NOTES) 5.2.5.1 Use ambient lay-up only if all of the following conditions apply: a. Drains are available at all low points to ensure complete removal of water. See ATTACHMENT 7 Notes b. Corrosion allowance has been provided, c. Pitting can be tolerated; and d. Particulate rust can be tolerated. 5.2.5.2 Remove all water from the system. For facilities other than pipelines, drain the system completely, sweep and mop as required to ensure that no visible traces of water remain. For pipelines, dewatering shall be performed by scraping with a three or four cup displacement scraper (or better) unless system limitations make this option impracticable. 5.2.5.3 After removal of all water, close the system to prevent the entry of sand or rainwater. 5.2.5.4 Install a vacuum breaker unless it is demonstrated that the system will not collapse under vacuum.

OTHER LAY-UP (SUCH AS VALVE CORROSION PREVENTION) Other lay-up methods are acceptable with the prior written approval of the Supervisor, CTU/ME&CCD/CSD, and, in cases where safety concerns may arise, t he approval of the Chief Fire Prevention Engineer, Loss Prevention Department.

THE END

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SAIC-A-2018


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ATT. 5 - LAY UP PROCEDURE (SPECIAL APPLICATIONS) Dry Gas & Refined Hydrocarbon Product Pipelines & Piping* 7.3.1 Hydrotest procedures for services in these categories under Pipelines Department jurisdiction shall be reviewed and approved by Pipelines Department: specifically, the General Supervisor, PTSD, and Manager of the respective area department. *This piping can extend into Plant Piping (ASME B31.3) 7.3.2 Prevent corrosion during hydrotest & lay-up procedures for sweet sales gas, ethane, refined products such as gasoline, kerosene, diesel, etc, and processed NGL. Corrosion products and other contaminants introduced during construction, hydrotesting, and start-up can create major problems for many years. 7.3.3 Remove all debris f rom line before hydrotesting using brush scrapers and magnetic scrapers. 7.3.4 For pipelines and piping in dry gas or refined hydrocarbon product service, oxygen scavenger shall always be added to the hydrostatic test water, even when the hydrotest water contact time is less than 14 days as specified in Para. 5.1. This does not apply to plant piping which shall be treated per Para. 5.1. Use batching scrapers and/or a slug of nitrogen to separate the air in the system from coming in contact with treated water, and then fill the system with treated water by injecting sufficient oxygen scavenger to maintain a minimum oxygen scavenger residual concentration of 20 ppm and an oxygen concentration less than 10 ppb. 7.3.5 Pipelines in dry gas or refined hydrocarbon product service shall be layed up using eit her the wet lay-up method per Paragraph 5.2.2 or the dry layup method with the line pressurized with dry sweet gas or dry nitrogen, but not air. 7.3.6 When water is finally removed from the pipe, either at the end of the hydrotest or at the end of a wet lay-up, the system shall be thoroughly dried. Air drying shall not be used f or pipelines. Air drying may be used for small in-plant piping systems if drying can be completed in no more than one week. Refined product lines which are generally small (about 14" or less) may be dried with nitrogen from skidmounted nitrogen generation units or from bulk tanks. Sweet gas pipelines that are generally large diameter will most usually be dried with sweet gas if available. Chemical desiccants such as glycol or methanol may also be used if necessary and specifically pre-approved in the hydrotest procedure. 7.3.7 An alternative to extensive drying operations & detailed hydrotest control is to use internal coatings to prevent corrosion and black powder formation. This decision must be taken early in the design process. Evaluate the economics of coating versus the economics careful hydrotest control. Obtain approval of the coating from the Supervisor, Cathodic Protection and Coatings Unit, Materials Engineering and Corrosion Control Division, CSD. Obtain approval of coating and hydrotest procedures from the Pipelines Dept: General Supervisor, PTSD, and Manager of the respective area department.

SOUR GAS & SOUR OIL PIPELINES 7.4.1 Hydrotest procedures for sour gas, sour oil, or sour multiphase lines under Pipeli nes Department jurisdiction shall be reviewed & approved by Pipelines Dept: specifically, the General Supervisor, PTSD, and Manager of the respective area department. 7.4.2 After the pipeline has been hydrotested, it shall be layed up following methods detailed in Para 5.2. 7.4.3 Prior to the introduction of sour process fluid into a new line, the line shall be dried. Drying is not required for existing lines. 7.4.4 Immediately prior to recommissioning new or existing lines, lines shall be batch treated with a corrosion inhibitor by using a slug of corrosion inhibitor between two or more scrapers. Slug size is calculated as follows: Gallons of inhibitor = Pipeline length (km) x pipeline diameter (in) x 3 7.4.5 Where there is an unavoidable delay between signature of the Mechanical Completion Certificate & introduction of fluids into the line, PMT shall provide sufficient funds to operating or other organization that will perform the inhibitor treatment to pay for all expenses associated with the inhibitor treatment. THE END

Page 8 of 12


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SAIC-A-2018


22-Jan-14

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ATTACHMENT 6 - LAY UP PROCEDURE (PLANTS- SPECIAL APPLICATIONS) Applications are for Plant Piping Systems & Equipment as clearly specified below. 7.5 Plant Piping 7.5.1 In general, new or existing pipework in plants & refineries will be hydrotested either on-site or in a plant fabrication shop. Due to the shorter physical length of this equipment, hydrotests can be effected in a shorter time than that which would require chemical treatment with oxygen scavengers or biocides per Para 5.1, 6.3, or 5.2.2. Therefore, unless these time limits are exceeded, no chemical treatment is req'd. 7.5.2 Due to the complexity of plant construction operations, often new plant pipework is laid up by drying following the requirements of 5.2.3 to achieve a dew point of -1°C. Drying is normally achieved within a plant using dry air or sometimes nitrogen. 7.5.3 Chloride limits for 3xx-series stainless steels must be strictly followed. 7.6 For any galvanized pipe not covered by Paragraph 7.2, treat galvanized steel pipe per paragraph 5.1 and lay-up per paragraph 5.2. 7.7 Water shall not require treatment if used to pressure test completely internally coated or lined equipment, or systems entirely fabricated with non-metallic materials. No lay-up procedure is required for totally non-metallic systems (e.g., PVC pipe). 7.8 Lube oil systems shall be pressure tested following the reqmts of SAES-L-150. Water shall not be used. 7.9 Instrument air systems shall be pressure tested following requirements of SAES-J-901 & SAES-L-150. Water shall not be used. 7.10 Boilers shall be laid up per SAEP-1026. 7.11 For heat exchangers, lay-up shall be required unless start up occurs within 14 days of commencing the hydrostatic test. 7.12 For yard or shop fabricated piping systems that are constructed abroad, hydrotested, then shipped to Saudi Arabia, PMT shall submit the hydrotest and layup procedure to the Supervisor, CTU/ME&CCD/CSD, for approval. In addition to one of the lay-up methods from Paragraph 5.2, the use of vapor phase corrosion inhibitors shall normally be required. 7.13 For all materials not specifically covered in this standard and for doubtful situations, obtain prior written clarification from the Supervisor, CTU/ME&CCD/CSD.

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. 8.3 Monitor chemical injection rates on site using displacement gauges.

9 Disposal 9.1 Hydrostatic test waters m ust be disposed per SAEP-327 and SAES-A-103. 9.2 Disposal plans must be approved prior to the start of any hydrotest.

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. 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 = suffocation. Page 9 of 12



Rev 3 SAIC NUMBER

SAIC-A-2018


22-Jan-14

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MECH-

ATTACHMENT 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT) STAINLESS STEEL SYSTEMS & EQUIPMENT (OPTION B) STEP # 1 (Oxygen Scavenger Rule) 6.3 Treat the hydrostatic test water with oxygen scavenger per paragraph 5.1* if the equipment contact equipment contact time with water might exceed 4 days. Oxygen Scavenger Appendix is in Attachment 8. 5.1 Treatment of Hydrostatic Test Water When equipment contact time with hydrotest water may exceed 14 days, an approved oxygen scavenger (Appendix 1) shall be added to the hydrostatic test water. Treat the water before it enters the system. Use batching scrapers and/or a slug of nitrogen to separate the air in the system from coming in contact with treated water, and then fill the system with water injecting sufficient oxygen scavenger to maintain its residual concentration at greater than 20 ppm and an oxygen concentration of less than 10 ppb. STEP # 2 (Apply Lay-Up Method using 30-day rule). See Special Notes Below. 6.4 Lay-up the system following the requirements of Paragraph 5.2*. Note: A Lay-up Method is selected. 5.2 Lay-up Procedures 5.2.1 Equipment must be laid-up after hydrotesting unless it can be ensured that it will be returned to service within 30 days from the first introduction of hydrotest water to the system. Use one of the lay-up methods detailed (Wet, Dry, Inert Gas, Ambient, Other in ATTACHMENTS 2, 3, or 4). See Paragraph 7 for requirements for specific systems (Note: Attachment 5 Does not normally apply to SS Systems). Lay-up procedures for pipelines under the responsibility of Pipelines Department shall be approved prior to hydrotest by the General Supervisor, Pipelines Technical Services Division (PTSD), and by the Manager of the concerned area. Approval of lay-up procedures for other equipment shall be the responsibility of t he Saudi Aramco Engineering Superintendent or his designate (Note: Pipelines are not normally SS). STEP # 3 (End Lay-up and Evaluate Condition/Corrosion as Necessary) 6.5 At the end of the lay-up, commission and start up the stainless steel equipment within 14 days.

SPECIAL CARE FOR 13Cr (400 Series) Trim SS VALVES Trim 8 is the most common type of valve used in Saudi Aramco Plants. This requirement was specifically cited for Pipelines, as severe corrosion occurs with extended improper Lay-up. CSD has stated that this also applies for Plant Piping. This is common sense & must be addressed in Plant Piping Pressure Testing & Valve Field Testing & Subsequent Lay-up Actions as follows: 1. Valves coming from the manufacturer are pressure tested and "lay-up" is "OT HER" or Special: a) Valve manufacturers takes great care to stroke valves and allow water "time" to descend from bonnets b) Water is then blown out using high pressure air until water is removed. Moisture is still present. c) Valve Manufacturer "APPROVED CORROSION-RESISTANT LUBRICANTS" are then professionally applied by trained valve testing technicians who distribute lubricant in effective methods to prevent rust. d) Valves are then stroked and lubricants are spread evenly over sealing surfaces to prevent corrosion. e) Valves are then coated and sealed/covered shipped to Saudi Aramco for installation in our facilities. f) Valve handling during shipping and Other* Concerns (age in storage, corrosion consideration, damage) requires the Safeguard of "FIELD TEST ING OF CRITICAL ISOLATION VALVES" per SAES-L-108. g) Valves are then again opened & inspected for warranty coverage for shipping damage/other concerns. h) Valves are field t ested (body test, high pressure seat test, other tests as required by SAES-L-108). CORROSION CONTROL CONSIDERATIONS ARE NOW THE RESPONSIBILITY OF THE CONTRACTOR!!! At a minimum, Contractor Procedure SHALL: 1. Apply the same lay-up and care after Valve Testing that was applied by the Valve Manufacturer. This includes careful drying and application of lubricants and corrosion control measures applicable. 2. Perform routine "PRESERVATION CHECKS" when valv es (13 Cr trim or 400 series SS) are stored longer then 30 days after field testing to assure effective corrosion control measures. 3. IF OPTION B IS SELECTED AND THE VALVE IS THEN TESTED IN-LINE, CONTRACTOR SHALL NOT ALLOW AMBIENT LAY-UP OF VALVES (13 Cr Trim or 400 Series SS). WHERE VALVES HAVE NO DRAIN, COMPLETE REMOVAL OF WATER FROM VALVE CAVITIES "SHALL BE DEMONSTRATED" to comply with SAES-A-007, Para. 5.2.5.1 a). Valves may be removed after test and treated similarly to Valve Testing. NOTICE: PROCEDURE SHALL DETAIL THE METHOD USED TO ASSURE COMPLETE REMOVAL OF WATER FROM VALVE CAVITIES, CORROSION CONTRO L MEASURES & PRESERVATION CHECKS DURING LAY-UP. FOLLOW UP VALVE CHECKS FOR CORROSION DEMONSTRATE EFFECTIVE PRESERVATION (LAY-UP). Page 10 of 12


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ATTACHMENT 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT) SAES-L-105 Valve Trim Table (Page 2/2)

SAES-L-105 Valve Trim Table & Notes Note: 400 Series SS = those mat'ls designated as 13 CR

Page 11 of 12



Rev 2 SAIC NUMBER

SAIC-A-2018


22-Jan-14

MECH-

ATTACHMENT 8 - SAES-A-007 Appendix 1 (Approved Oxygen Scavengers)

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Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Internal Cleaning for Plant Systems, Plant Equipment and Pipelines PROJECT TITLE

SAIC-L-2001 WBS / BI / JO NUMBER




REV. NO.




22-Jan-14

QR NUMBER

PIPE-


EQPT CODE

SYSTEM ID.


PLANT NO.


MH's SPENT

TRAVEL TIME





ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

A

General Requirements (See also Section F for Pipelines)

A1

The procedure is identified and traceable to the project's updated list of quality documents.

Sch. Q, Att IV

A2

During project proposal and detailed design, detailed procedures for cleaning and flushing of the piping spools and systems shall be established identifying acceptable methods that will be applicable for every individual system category. These procedures shall be agreed on by PMT, Proponent and Inspections Agency.

SAES-L-350 Para. 15.1/ S-PMG000-3160-0801 Sec. 11

A3

All sensitive equipments to damage during cleaning and flushing of the piping system shall not be installed and shall be removed if installed prior SAES-L-350 to commencing the cleaning process. The list of these equipments shall Para. 14.1/ S-PMbe established during early stages of execution of the project. Example G000-1520-0007 of sensitive equipment are: rotating machinery, orifices, control valves, Para. 8.1.4 flow elements, soft-seated valves, globe valves, etc. Complete this list based on workscope.

A4

Inspection strategies and plans shall be prepared and agreed on prior to commencing of fabrication and erection.

B

Requirements Prior to Installation (Before Pipe goes on rack or supports)

SAES-L-350 Para. 17.2/ S-PMG000-3160-0801 Sec. 10

B1

Prior to Installation (Cleaning Requirements) for Procedure: As a minimum & prior to installation and/or erection of pipe spools on pipe racks & pipe supports the following shall be conducted: A) All pipes shall be internally cleaned by air blowing. Also, large diameter pipe is rag cleaned (brushed, swept) as practical to do so. B) All prefabricated pipe spools shall be visually inspected for cleanliness, & shall have foreign material removed from the inside. C) Piping ends shall be covered after inspection to prevent the unauthorized removal of end covers prior to making the joint to the succeeding section of piping. D) Method of covering pipe ends shall be part of the procedure.

B2

Contractor procedure requires "All piping systems and components to be SAES-L-350 inspected and verifed to be internally clean and free from foreign Para. 14.2/ S-PMobjects/materials BEFORE piping goes on racks or supports" G000-3160-0801 Para. 8.2 Methods to accomplish this shall be stated in procedure.

C

Requirements During Installation (During Assembly and Erection)

C1

During Assy & Erection (Cleaning Reqmts) for Procedure: During assembly & erection, the construction agency shall ensure that no foreign materials (such as welding consumables, lumbers, gloves, etc.) are left inside the piping system.

C2

Contractor procedure requires "All piping systems and components to be SAES-L-350 inspected and verified internally clean and free from foreign objects and Para. 14.2/ S-PMmaterials "DURING ASSY & ERECTION PROCESS". G000-3160-0801 Para. 8.2 Methods to accomplish this shall be stated in procedure.

Page 1 of 5

SAES-L-350 Para. 15.2/ S-PMG000-1520-0007 Para. 8.1.2

SAES-L-350 Para. 15.3.1/ SPM-G000-31600801 Para. 8.2


PASS

FAIL

N/A

RE-INSP DATE


Rev 3


ITEM No.

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE


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PASS

FAIL

N/A

RE-INSP DATE

D

REQUIREMENTS AFTER ASSEMBLY & INSTALLATION (PRE-PRESSURE TEST) INCLUDING SAFEGUARDS BEFORE TESTING

D1

SAES-L-350 Contractor procedure lists all sensitive equipment susceptible to damage Para. 14.1/ S-PMduring all types of cleaning and flushing of piping systems, such as G000-1520-0007 rotating machinery, control valves, soft-seated valves, globe valves, Para. 8.1.3 & relief valves, orifice plates, flow-elements,etc. 8.1.4

D2

Contractor procedure contains a safeguard statement to protect all SAES-L-350 sensitive equipment by requiring removal from system prior to cleaning Para. 14.1/ S-PMand flushing if equipment has already been installed before cleaning and G000-1520-0007 flushing. The procedure must also cover methods for protection of Para. 8.1 flange face finish during cleaning to prevent damages.

D3

After assembly and installation, assembled piping shall be cleaned by one or more of the methods outlined in Appendix A or by a pre-agreed upon procedure to be approved by Company.

S ee Attachment 1 (Cleaning & Flus hing of Plant Piping ) Follow above listed Safeguards Pr ior to cleaning activi ties

D4

After assembly & installation, piping shall have cleanliness verified visually and/or by video inspection techniques. 1) Mirror & Natural Light are best/cheapest methods to use. 2) Certain applications require use of borescope or use of RT, such as header piping & U-bends in Boilers, critical headers in certain services (Hydrogen, etc) & Fired Process Heater. RT is effective in the identification of foreign objects & obstructions such as welding electrodes & other foreign objects that can cause tube failures. 3) For critical applications, RT SHALL BE PERFORMED per the requirements of S-PM-G000-1520-0011, Par. 19.2. (SEE NOTES BELOW).This is cheap insurance to assure critical system integrity.

SAES-L-350 Para. 15.3.2/ SPM-G000-31600801 Sec. 11

SAES-L-350 Section 15/ S-PMG000-3160-0801 Sec. 11

E

SPECIAL CLEANING REQUIREMENTS (Chemical, Vapor Phase or Foam Cleaning)

E1

Procedure shall come from qualified & approved chemical cleaning contractors with Company approval. Procedures shall describe in detail the steps for degreasing, descaling, neutralization, and passivation.


E2

Lines to be chemically cleaned shall be identified on P&ID's & Line Index. Systems to be cleaned shall have high & low point vents and drains installed.


E3

The procedure shall state the purpose and sequence of Chemical, Vapor Phase or Foam cleaning of the interior of the piping. Piping shall be cleaned after hydrostatic pressure testing to remove oil, grease, preservatives, rust and mill scale per approved procedures


E4

Procedure shall list the following services that require specialty cleaning and show the type of required cleaning involved for each along with references to Company requirements: a) Boiler feed water and steam condensate. b) Lube oil and seal oil. c) Seal gas supply piping. d) Steam supply line to turbines. e) DGA, TEG, and Refrigerant systems. f) Where and If necessary to meet service fluid quality.


Page 2 of 5


Rev 3


ITEM No.

E5

E6

SAIC NUMBER

SAIC-L-2001

22-Jan-14


ACCEPTANCE CRITERIA

REFERENCE

QR NUMBER

PIPE-


PASS

FAIL

N/A

RE-INSP DATE

SAES-L-350 The procedure for specialty cleaning of systems listed i n the above item Para. 15.4.1/ S#27 lists references to Company requirements 01-SAMSS-017, SAES-GPM-G000-3160116, and SAEP-1024 as applicable 0801 Para. 11.3 Procedure references & addresses SAES-G-116, Cleanliness Standard for Lube/Seal Oil & Fluid Power Systems: A) Cleaning/flushing per applicable procedures in SAEP-1028. B) Clean new lube/seal oil or fluid power system per SAES-G-116. C) Cleaning is accomplished by a combination of: • Mechanical cleaning • Flushing • Steam cleaning • Hot alkaline treatment • Acid/EDTA cleaning • Neutralization and passivation


E7

Procedure references and addresses SAEP-1024, Chemical Cleaning of New Boilers and associated piping and tubing and specific cleaning requirements as follows: The procedure defines the minimum requirements for cleaning all newly installed boilers to remove internal construction debris, including oil, grease and mill scale, prior to operation.


E8

Procedures for cleaning details disposal of hazardous chemicals and flushing water is in accordance with appropriate environmental concerns, Company approved methods and restrictions

SAEP-327 Section 3

E9

Procedures for specialty cleaning with chemicals require gasket replacement and treatment of used gasket as hazardous waste. Mandatory replacement & accounting for gaskets (by insp) is required when Chem Cleaning is done. Detail method to assure all new gaskets are installed in lines (not reused)

F

Requirements AFTER ASSEMBLY & INSTALLATION (PRE-PRESSURE TEST)

F1


The pipeline shall be cleaned per a detailed procedure that will account for end service. (Note Safeguards in D1, D2). For example, flowline in crude service may not require an extensive cleaning procedure while a sales gas pipeline connecting to master gas system requires more extensive cleaning procedures. Noteworthy is the new requirement for 400 Series trim (13 CR) Stainless Steel Valves in SAES-A-007. Cleaning and flushing through these valves should not be permitted, unless the valve will be removed, cleaned, inspected and preserved per SAES-A-007.


SAES-L-450 Para. 18.1, 2

REMARKS: NOTES: Often, Borescope inspection is impractical for applications. Contractor has approval to use Radiography here. In no case, shall this critical application remote visual inspection (Verification of Cleanliness) be neglected. Contractor Quality Manager has the responsibility to assure this requirement is not overlooked. Attachments: 1 - SAES-L-350, Appendix A – Cleaning and Flushing of Plant Piping Systems REFERENCE DOCUMENTS: 1. SAES-L-350, Construction of Plant Piping, (30 September, 2003) 2. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) 3. SAES- A-004, General Requirements for Pressure Testing, (30 March, 2005) 4. SAEP-1028, Chemical Cleaning and Flushing of Lube/Seal Oil and Fluid Power Systems, (3 July 2007) 5. SAES-G-116, Cleanliness Standard for Lube/Seal Oil and Fluid Power Systems, (30 July, 2003) 6. 01-SAMSS-017, Auxiliary Piping For Mechanical Equipment, (29 June 2005) 7. SAEP-327, Disposal of Wastewater from Cleaning, Flushing, and Dewatering Pipelines and Vessels (15 April 2007)

Page 3 of 5


Rev 3 SAIC NUMBER




ITEM ACCEPTANCE CRITERIA REFERENCE No. 8. SAEP-1024, Chemical Cleaning of New Steam Generating Equipment (3 July 2007)

22-Jan-14

QR NUMBER

PIPE-


PASS

FAIL

N/A

RE-INSP DATE

9. S-PM-G000-1520-0007, General Requirements for Pressure Testing 10. S-PM-G000-3160-0801, Construction Requirement for Piping Work


Company


Company PMT


T&I Witnessed

QC Record Reviewed

W ork Verified

T &I W it ne ss ed


Work Verified

T &I W it ne ss ed


Work Verified


QC Inspector





QC Supervisor





Y = YES

Page 4 of 5

N = NO F = FAILED


Rev 3


SAIC NUMBER



22-Jan-14

QR NUMBER

PIPE-


Attachment 1 - SAES-L-350, Appendix A – Cleaning and Flushing of Plant Piping Systems

Page 5 of 5


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Piping / Equipment Internal Cleaning Inspection PROJECT TITLE

SAIC NUMBER


SAIC-L-2017

22-Jan-14





REV. NO.


MECH-


EQPT CODE

SYSTEM ID.



QR NUMBER

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

MH's SPENT

TRAVEL TIME





ITEM No.

ACCEPTANCE CRITERIA

REFERENCE


PASS

A

General Requirements (Note: Use S ATR -A-2008 to document findings using this checklist )

A1

Method of cleaning & flushing of piping spools & systems applicable for every individual system category was approved/agreed upon by PMT, Proponent and Inspection. (SAES-A-004, Para. 7.1.2 )


A2

Visual verification of end limits covered by this inspection conformed with the QR (Quality Request for inspection)


B

Progressive Internal inspection (DURING ASSEMBLY)

Spools are visually inspected for internal cleanliness (no presence of loose particles/flakes or debris) prior to welding/bolting to the preceeding and/or succeeding spools. (Follow Notes Below) B1 A) Visual inspection includes use of video inspection techniques, visual, scraping & positioning in vertical position. B) Fine dusts are acceptable, unless specified for critical systems

B2

Ends of Piping spools or partially completed piping system passed visual inspection for internal cleanliness, were covered & sealed to prevent entry of debris (moisture, water or other foreign materials). Note: Each section of cleaned spools or system shall be recorded

End covers were not and cannot be removed by unauthorized personnel prior to making the joint of succeeding sections of piping. A) QA/QC and/or Company Project Inspection shall be notified B3 prior to removal of the end covers. B) End covers removed without authorization shall make the internal cleanliness null and void.

B4

C

Partial cleanliness inspection certificates for each section of a completed system are accounted for. Note: Where cleanliness cannot be fully verified, systems shall be cleaned by Method 2 or 3, whichever is applicable.)

SAES-L-350, Para. 15.3.2/ SPM-G000-31600801 Para. 8.2.1 SAES-L-350, Para 15.2.3/ SPM-G000-15200007 Para. 8.1.2

SAES-L-350, Para 15.2.3/ SPM-G000-15200007 Para. 8.1.2


Internal Cleaning by Water Flushing

C1

Equipment sensitive to damage during water flushing are identified and isolated. (Ex: Flow meter, sight glass, soft-seated valves )

S-PM-G000-15200007 Para. 8.1.4

C2

Equipment and in-line instruments that may interfere with the flow of water and debris are removed. ( Ex: check valve, control valve, sight glasses,orifice plates, venturies, positive displacement and turbine meters and other in-line equipment., etc. )

S-PM-G000-15200007 Para. 8.1.4

Full bore valves (ball & gate valves) are in full open position.

SAES-L-350, Appendix A/ SPM-G000-15200007 Para. 8.3.2

C3

Page 1 of 5

FAIL

N/A

RE-INSP DATE


Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST Piping / Equipment Internal Cleaning Inspection PROJECT TITLE

ITEM No.

C4

SAIC NUMBER


ACCEPTANCE CRITERIA

REFERENCE

Flushing medium used are any of the following: A) Plant/process water B) Raw water (Fire water OK when process water is not available) Note: Sea water is not acceptable For stainless steel lines, flushing medium chloride ion content is less than 50 mg/L. (NOTE: After flushing, the piping systems shall be completely drained, dried to a dew point below -1°C )

C6

For lines below 4" dia., minimum velocity of water fushing is 3 m/s.

SAES-L-350, Appendix A

C7

For lines 4" dia. and above, high pressure jet (rotating hose or nozzle) at a minimum pressure of 60.8 mPa (8.8 psi) is used.


D

Pneumatic Flushing

D1

Medium used for pneumatic flushing is dry air (dew point -1°C or less) or steam with a minimum exit velocity of 15 m/s.


D2

Flushing is repeated until cleanliness is verified by observing the absence of any solids impact on a polished metal target at the exit.


22-Jan-14

Pressurized Air Shock Blowing (PASB)

E1

PASB method is used for the following conditions: a. For initial cleaning of instrument air, plant air b. As an alternative method for initial cleaning of small bore pipe (less than 2 inch). c. Presence of trapped liquid in the piping, or if verification of cleanliness using video inspection is not possible.


E2

The air shocking pressure shall never exceed the working pressure of the system and shall never be more than 810 kPa (115 psi).


E3

Safety precautions are considered in consultation with Area Loss Prevention Division.


E4

PASB is repeated until cleanliness is verified by observing the absence of any solids impact on a polished metal target at the exit.


PASS

FAIL

Mechanical Scrapers

F1

Mechanical scrapers are used on piping system that will not cause damage to the pipe interior surface (ie: piping with internal coating).


F2

Degree of cleanliness conforms with the approved internal cleaning procedure.


F3

Internal scrapers have full bore contact with the pipe diameter. Additional checkpoints or Acceptance Criteria shall be added upon approval of Piping Internal Cleaning Procedure by scraping.

Procedure detail Procedure detail

REMARKS: ATTACHMENT: 1. SATR-A-2008, Piping / Equipment Internal Cleaning Inspection NOTES FOR SATR-A-2008 USE: Note 1: Method of internal cleaning states in detail the cleaning methods used (reference Company approved procedure) Note 2: Limits of internal cleaning state whether cleaning was full or partial and details the system limits for cleaning (specific line #) and/or equipment details/limits "as inspected" Note 3: Type of Debris found states what was found during cleaning and any other unusual findings that could affect system integrity "as inspected"

Page 2 of 5

QR NUMBER

MECH-


S-PM-G000-114Z0003 Para. 8.1.1

E

F4

DATE APPROVED


C5

F

30-Jun-08

N/A

RE-INSP DATE


Rev 3 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST Piping / Equipment Internal Cleaning Inspection

DATE APPROVED

SAIC-L-2017

PROJECT TITLE

30-Jun-08


QR NUMBER

22-Jan-14

MECH-


ITEM ACCEPTANCE CRITERIA REFERENCE PASS FAIL No. Note 4: Valve Cavity & other system low point component cl eaning states exactly how low points remaining in line or the

N/A

RE-INSP DATE

equipment were cleaned. methods are adequate for removal of debris (sample selected by Company to witness shall demonstrate this). See Explanation below. Explanation: Valves should be installed in systems AFTER pressure testing when possible during system reinstatement. THE ABOVE STATEMENT IS CLEARLY STATED AND INTENDED IN SAUDI ARAMCO STDS TO PREVENT VALVE SEAT DAMAGE. Code fabricated test implements can easily replace valves during system hydrotests. Cavities & other low points in the line where debris can accumulate require special attention during cleaning. Typical flushing with air or water is inadequate in the removal of debris from valve cavities and low points. This accumulated debris (sand, scale, metal shavings, slag, etc) creates serious corrosion and operational problems for COMPANY. Cleaning methods shall demonstrate adequate cleaning for all piping system components and equipment. Where items such as valve cavities exhibit an inadequate level of cleanliness, adequate cleaning & inspection shall be performed at earliest opportunity and addressed no later than immediately after hydrotest. Avoid flushing lines through valves & install field hydrotested valves "after" system testing where possible. Preservation checks of valves utilizing "AMBIENT" Lay-up methods is required. REFERENCE DOCUMENTS: 1. 2. 3. 4. 5.

SAES-A-004, General Requirements for Pressure Testing, (30 march, 2005) SAES-L-350, Construction of Plant Piping, (30 September, 2003) SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) S-PM-G000-1520-0007, General Requirements for Pressure Testing S-PM-G000-3160-0801, Construction Requirement for Piping Work


Company


Company PMT



QC Inspector

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

W ork Verified




QC Supervisor Name, Sign and Date:


Proponent and Others Name, Organization, Initials and Date:


Y = YES

Page 3 of 5

N = NO F = FAILED


Rev 3 SAIC NUMBER

SAUDI ARAMCO TEST REPORT Internal Cleanliness Report (Piping Systems & Equip)

DATE APPROVED

SATR-A-2008

PROJECT TITLE

30-Jun-08


QR NUMBER

22-Jan-14

MECH-




TEST SYSTEM No./Test Pack No.

PLANT NO.

DRAWING NUMBER (P&ID/ISO) / REV. No.

PIPE CLEANING DIAGRAM (If applicable)

LOCATION

WORK PERMIT REQD?

SCHEDULED TEST DATE & TIME

ACTUAL TEST DATE & TIME

SAUDI ARAMCO TIP (SATIP) NUMBER

SATIP Activity No.

TEST IN ACCORDANCE WITH:

a) Procedure No.

b) Supporting SAIC No.

System Description: Service Fluid:

MAOP:

System Material Type:

Internal Cleanliness Report for On-Plot Piping & Equipment (See Remarks) Method of internal cleaning (For piping systems and equipment)

Limits of internal cleaning (State Partial or Full and terminating ends)

Type Of Debris (sand, mill scale, electrodes, debris, etc.)

Valve Cavities & Other Low Point System Components

Internal Cleanliness Report for Pipelines (Note 2) Pipeline Description : ____________________________________________ Pipe Internal Diameter(s): _________________ Drawing No:

Location / Date

Section No:

Test No:

From KM:

To KM:

Scraper Type

RUN 1 DATE

RUN 2 TIME

DATE

RUN 3 TIME

DATE

REMARKS TIME

Cleaning Start Cleaning End Cleaning Duration

OBSERVATIONS: 1. Indicate Amount and/or type of debris 2. Scraper

RESULT (ACC/REJ) REMARKS:


Company


Company PMT



QC Inspector

QC Record Reviewed

Work Verified

T &I W it ne ss ed

QC Re co rd Rev ie we d

Work Verified

T &I W it ne ss ed

QC Re co rd Rev ie we d

Work Verified





QC Supervisor



T&I Witnessed


Page 4 of 5


Y = YES

Page 5 of 5

N = NO F = FAILED

SATIP a 004 02 Hydrostatic of on Plot Piping

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