Engineering Standard

SAES-A-004

30 March 2005

General Requirements for Pressure Testing

Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards

Table of Contents

1
2
3
4
5
6
7
8
9

Scope............................................................. 2
Conflicts and Deviations................................. 2
References..................................................... 2
Definitions....................................................... 5
General Requirements................................... 5
Specific Testing Requirement........................ 8
Test Preparation........................................... 11
Test Procedures........................................... 13
After Completion of Pressure Test............... 14

Appendix I - Sample Form of Request for

Non-Destructive Testing In-Lieu of
Hydrostatic Test........................................... 16
Appendix II - Sample of SA2642-ENG
Pressure Test Report Form......................... 17

Previous Issue: 30 June 2003 Next Planned Update: 1 April 2009

Revised paragraphs are indicated in the right margin
Primary contact: Patrick T. McGhee on 873-6486

Page 1 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

Scope
1.1

This standard defines mandatory general requirements governing in-situ

pressure testing of new and existing pipelines, plant piping and pressure
containing process equipment (hereinafter called equipment). Specific
requirements are covered in the specific SAESs applicable to that equipment or
piping system. This standard supplements ASME B31's and other applicable
codes.

1.2

The requirements of this standard apply to field/shop fabricated piping systems

and field fabricated equipment.

1.3

This standard does not cover pressure testing of new, shop fabricated equipment
such as vessels, tanks, heat exchangers and skid mounted piping which are
purchased in accordance with the applicable SAMSS.
Exception:
Fin-fan coolers are to be tested in situ in accordance with paragraph 6.4.5.

1.4

This standard applies to pre start-up leak tests normally conducted by

Operations during start-up, commissioning and T&I of the facilities in
accordance with approved plant operating procedures.

1.5

This standard does not apply to equipment as excluded in section 7.2.

Conflicts and Deviations

2.1

Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAES's), Materials System Specifications (SAMSS's),
Standard Drawings (SASD's), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Inspection Department of Saudi Aramco, Dhahran.

2.2

Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Inspection Department of Saudi
Aramco, Dhahran.

References
The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities required by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.

Page 2 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

3.1

SAES-A-004
General Requirements for Pressure Testing

Saudi Aramco References

Saudi Aramco Engineering Procedures
SAEP-302

Instructions for Obtaining a Waiver of a

Mandatory Saudi Aramco Engineering
Requirement

SAEP-327

Disposal of Wastewater from Cleaning, Flushing,

and Dewatering Pipelines and Vessels

Saudi Aramco Engineering Standards

SAES-A-005

Safety Instruction Sheet

SAES-A-007

Hydrostatic Testing Fluids and Lay-up

Procedures

SAES-B-017

Fire Water Systems

SAES-D-008

Inspection, Repairs, Alteration, Rerating and

Testing of Existing Pressured Equipment

SAES-D-108

Storage Tank Testing and Inspection

SAES-H-101

Saudi Aramco Paint and Coating Systems

SAES-K-001

Heating, Ventilating and Air-Conditioning

SAES-L-108

Selection of Valves

SAES-L-150

Pressure Testing of Plant Piping and Pipelines

SAES-L-350

Construction of Plant Piping

SAES-J-901

Instrument Air Supply Systems

SAES-S-020

Industrial Drainage and Sewers

SAES-S-030

Storm Water Drainage

SAES-S-040

Saudi Aramco Water Systems

SAES-S-060

Saudi Aramco Plumbing Code

SAES-S-070

Installation of Utility Piping Systems

Saudi Aramco Materials System Specifications

01-SAMSS-010

Fabricated Carbon Steel Piping

04-SAMSS-048

Valve Testing and Inspection Requirements

32-SAMSS-004

Manufacturing of Pressure Vessels

32-SAMSS-005

Manufacturing of Atmospheric Tanks

Page 3 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

32-SAMSS-006

Manufacturing of Low Pressure Tanks

32-SAMSS-021

Manufacturing of Industrial Watertube Boilers

32-SAMSS-029

Manufacturing of Fired Heaters

Saudi Aramco Form and Data Sheet

Form 2642-ENG

Pressure Test Report Form

Saudi Aramco General Instructions

GI-0002.102

Pressure Testing Safely

GI-1781.001

Inspection, Testing and Maintenance of Fire

Protection Equipment

Saudi Aramco Bottled Gas Manual Section V

3.2

Industry Codes and Standards

American Petroleum Society
API RP 520

Part I - Sizing, Selection, and Installation of

Pressure Relieving Devices in Refineries

American Society of Mechanical Engineers

ASME B31.1

Power Piping

ASME B31.3

Process Piping

ASME B31.4

Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids

ASME B31.5

Refrigeration Piping

ASME B31.8

Gas Transmission and Distribution Piping

Systems

ASME B31.9

Building Services Piping

ASME SEC V

Article 10 Leak Testing

ASME SEC VI

Recommended Rules for the Care and Operation

of Heating Boilers

ASME SEC VIII D1 & 2 Boiler and Pressure Vessel Code

National Board of Boiler and Pressure Vessel Inspectors
NB 23

National Board of Inspection Code

Page 4 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

Definitions
Hydrostatic Test: A pressure test conducted using water or other approved liquid as
the test medium.
Pre Start-up 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, during
commissioning or after T&Is.
Pneumatic Test: A pressure test conducted using air or other approved gas as the test
medium or in conjunction with liquid.
Pressure Test: A test conducted to piping or equipment by subjecting it to an internal
pressure using liquid or gas to ensure strength or tightness of the system at the test
pressure.
Revalidation Test: A pressure test performed to prove the integrity of existing piping
or equipment. This test is administered by the proponent organization.
Service Test: A pressure test conducted at operating pressure using the service fluid.
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 or
equipment for service at the design pressure.
System Test: An in-situ pressure test applied to a group of piping and equipment tested
as a system.
Pressure Test Procedure. Information assembled to ensure all requirements listed in
GI-0002.102 , all referenced Saudi Aramco standards and Industrial standards are met.
Tightness Test: A pressure test to ensure tightness of the piping system (i.e., no leaks
in the system) at the test pressure.

General Requirements
5.1

General Instruction GI-0002.102 "Pressure Testing Safely" shall be followed

during pressure testing.

5.2

Pneumatic testing
5.2.1

Pneumatic testing is not permitted without written approval of the

Manager, Inspection Department, unless specifically allowed by this
standard or the referenced Saudi Aramco SAESs or SAMSSs. This test,
when conducted, shall be in accordance with GI-0002.102 for additional
safety requirements.
Page 5 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

5.2.2

SAES-A-004
General Requirements for Pressure Testing

Pneumatic testing with air of piping systems or equipment which have

been in flammable service shall be concurred by the Manager, Loss
Prevention Department.

5.3

The effect of the static head of the testing liquid shall be considered when
determining the effective test pressure of any elements within a tested system.

5.4

Test pressures and test durations shall be based on the applicable Aramco
standards.

5.5

Protection from Overpressure

All systems (piping and equipment) while being pressure tested shall be
protected from being overpressured by the following:
5.5.1 Relief valve(s) of adequate capacity set to relieve at 5% above the test
pressure shall be installed unless the test pressure is less than 85%
SMYS at which time it can be set at 10% above the test pressure. Sizing
of these relief valves used for testing shall follow the requirements of
API RP 520, Part 1. The relief valve(s) shall be tested, dated, and tagged
within one week prior to the pressure test for new construction projects,
and within one month for maintenance operations.

5.6

5.5.2

In addition to the pressure relieving device, a bleed valve shall be

provided to protect the piping and equipment from overpressure. The
bleed valve shall be readily accessible in case immediate
depressurization is required.

5.5.3

An isolation valve shall be provided between the pressure testing

manifold and the system being tested. The isolation valve shall be rated
for the manifold test pressure when in the closed position.

5.5.4

Before employing the pressure testing manifold in the actual system

pressure test, it shall be separately pressure tested to at least 1.2 times the
system test pressure but not less than the discharge pressure of the pump
used for the pressure testing.

Pressure Test Procedure

5.6.1

A pressure test procedure shall be prepared by the responsible

engineering group and made available to Inspection prior to conducting
the test. The test procedure shall be available on site at all times.
The pressure test procedure shall include all required documentation
specified in GI-0002.102, paragraph 5.2.

Page 6 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

During a pneumatic pressure test a leak test shall be performed in

accordance with ASME SEC V Article 10 and Article 10 Appendix I
except the pressure shall be 5 10 psi instead of the design pressure. A
calculation sheet indicating adequacy of the test Relief Valve shall be
included in the procedure.
5.6.2

A request for NDT in lieu of pressure testing shall be submitted for

approval as permitted in the specific SAES listed in Section 6 below. A
sample form is provided in Appendix I. This form or an equivalent shall
be processed prior to NDT.
Commentary Note:
The plant manager will sign the form for existing facilities and the
Inspection Department Manager will sign for new construction projects.

5.7

The requirement for pre start-up leak tests and service tests during initial start-up
and T&Is shall be as follows:
5.7.1 New systems after strength tests and prior to initial start-up:

5.7.2

5.7.1.1

For systems with maximum operating pressures greater than

6.894 MPa (1000 psi), a leak test with inert gas, followed by a
service test, shall be conducted at the maximum operating
pressure of the piping system. Oil flowlines, trunklines,
testlines and water injection lines are excluded from this
requirement.

5.7.1.2

For systems with maximum operating pressures less than 6.894

MPa (1000 psi), a pre start-up leak test with inert gas or steam
(if designed for steam service) shall be conducted at the
available inert gas or steam system pressure (not exceeding the
maximum operating pressure), or pressure as recommended by
responsible Operation Engineering Unit, followed by a service
test at normal operating pressure of the piping systems. When
inert gas or steam are not available, the service test will satisfy
the pre start-up leak test requirements.

Existing systems after T&Is:

5.7.2.1

For systems with maximum operating pressures greater than

6.894 MPa (1000 psi) which are in hydrogen service or in sour
service with hydrogen sulfide concentrations higher than 0.1
mole %:

Page 7 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

5.7.2.1.1

A pre start-up leak test with inert gas shall be

conducted after major T&Is. The test pressure shall
be determined by the plant Operating Department.
For minor T&Is, the pre start-up leak test shall be
conducted per 5.7.2.2.

5.7.2.1.2

The pre start-up leak test shall be followed by a

service test at the normal operating pressure of the
piping.
Commentary Note:
A major T&I is defined as either a catalyst change
or a major disassembly of flanges, gaskets, etc.
The local Operation Engineering Unit and
Inspection Unit have the responsibility to define
when a T&I is considered as major. This definition
must be made during the pre-T&I scope of work to
allow Operations sufficient time to have inert gas
on-site prior to start-up of the facility.

5.8

5.7.2.2

For all other systems and pressures, a pre start-up leak test with
inert gas or steam (if designed for steam service) shall be
conducted at the available inert gas or steam system pressure
(not exceeding the maximum operating pressure), or at pressure
as recommended by responsible Operation Engineering Unit,
followed by a service test at normal operating pressure of the
piping systems. When inert gas or steam are not available, the
service test will satisfy the pre start-up leak test requirements.

5.7.2.3

Procedures for both pre start-up leak tests and service tests shall
address, to the extent possible, the safety precautions provided
in GI-0002.102 "Pressure Testing Safely".

If the drop in ambient temperature may cause the test medium to freeze during
the test, appropriate precautionary measures must be taken to protect the
equipment or piping systems.

Specific Testing Requirement

This section specifies in details which piping or equipment that shall be pressure tested
and provides the specific applicable standard. It also defines any specific exemptions.
6.1

Plant Piping
Pressure testing of plant piping shall be in accordance with SAES-L-150.

Page 8 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

6.2

SAES-A-004
General Requirements for Pressure Testing

Cross-Country Pipelines
Pressure testing of cross country pipelines shall be in accordance of SAES-L-150.

6.3

Pressure Vessels
6.3.1

Hydrostatic testing for new vessels (shop or field fabricated) shall be

conducted as follows:
ASME Section VIII, D1 to SAMSS-004, Paragraph 16.3.8.1.
ASME Section VIII, D2 to SAMSS-004, Paragraph 16.3.8.2.

6.4

6.3.2

Hydrostatic testing for existing vessels shall be conducted per SAES-D008, Paragraph 10.1.

6.3.3

Pneumatic test, when approved (refer to paragraph 5.2), shall be

conducted per UG-100 of ASME SEC VIII D1, or T-4 of ASME SEC
VIII D2, whichever is applicable.

Heat Transfer Equipment

6.4.1

Hydrostatic tests for existing equipment shall be in accordance with

SAES-D-008.

6.4.2

For pneumatic testing, refer to paragraph 6.3.2.

6.4.3

Hydrostatic testing of new, field fabricated boilers shall be in accordance

with 32-SAMSS-021. For pressure testing after repair or alteration, refer
to SAES-D-008 and National Board Inspection Code, NB-23.
Hydrostatic test during T&Is shall be in accordance with the test pressure
as specified on boiler's safety instruction sheet.
Hydrostatic test for new, field fabricated heater tube assembly shall be in
accordance with 32-SAMSS-029.

6.4.4

Tube bundles which have been removed from the exchanger shell for
maintenance purposes, shall be subjected to an in-situ shell side test per
6.4.1 prior to returning to service.

6.4.5

Fin fan exchangers shall be strength tested in-situ for the following
cases:
6.4.5.1

Prior to final acceptance for all new projects, and

6.4.5.2

For maintenance purpose if exchanger has been transported.

Page 9 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

6.5

6.6

SAES-A-004
General Requirements for Pressure Testing

Tanks
6.5.1

For new, field fabricated tanks, the hydrostatic testing shall be in

accordance with 32-SAMSS-006 for large, low pressure welded tanks; or
32-SAMSS-005 for atmospheric steel tank.

6.5.2

For existing tanks, the hydrostatic testing shall be in accordance with

32-SAMSS-005/006 as applicable.

Fire Protection Systems

Pressure testing of new and existing fire protection systems shall be in
accordance with SAES-B-017 and GI-1781.001.

6.7

Refrigerant Piping Systems

Refrigerant piping serving building air conditioning systems shall be tested
according to the requirements of SAES-K-001 and the Uniform Mechanical
Code (UMC), Section 1520.

6.8

Potable Water Systems

Potable water piping inside buildings shall be tested in accordance with the
requirements of the Uniform Plumbing Code (UPC). Exceptions to UPC
requirements are listed in SAES-S-060.
Potable water piping outside of buildings shall be tested in accordance with the
requirements of SAES-S-040.

6.9

Utility Piping Systems

Utility piping systems, including irrigation piping and water distribution mains,
shall be tested in accordance with SAES-S-070.

6.10

Industrial Drainage and Sewers

Industrial drainage and sewers shall be tested in accordance with SAES-S-020.

6.11

Sanitary Sewers
Sanitary sewer systems within buildings shall be tested per requirements of the
Uniform Plumbing Code (UPC). Exceptions to UPC requirements are listed in
SAES-S-060.
Sanitary sewer lines outside of buildings shall be tested in accordance with
SAES-S-070.

Page 10 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

6.12

SAES-A-004
General Requirements for Pressure Testing

Storm Water Drainage Systems

Storm water drainage systems shall be tested per SAES-S-030.

6.13

Miscellaneous Building Services Piping

Steam and condensate piping outside the jurisdiction of ASME B31.3, heating
and cooling water piping, vacuum and compressed air system piping for
building services shall be tested per requirements of ASME B31.9, Building
Services Piping.

6.14

Gas Cylinders
Gas cylinders shall be tested per Saudi Aramco Bottled Gas Manual.

6.15

Valves
Valves shall be tested in accordance with SAES-L-108.

6.16

Non Metallic Piping

Non metallic piping such as RTR, Thermoplastic, PVC/UPVC and CPVC shall
be tested in accordance SAES-S-070.

Test Preparation
7.1

Site Preparation
7.1.1

An approved test procedure shall be available at the site prior to

commencing any pressure testing activities.

7.1.2

New piping systems shall be cleaned in accordance with SAES-L-350.

7.1.3

Soft seated valves and control valves shall not be installed until after the
lines have been thoroughly flushed.

7.1.4

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.

7.1.5

Pressure gauges and pressure recorders shall be calibrated before the

tests.
a)

The calibration interval shall not exceed one (1) month.

Calibration certificates shall be made available to Inspection
Page 11 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

personnel prior to commencement of the pressure test. Stickers

shall be applied indicating the latest calibration date.

7.1.6

7.2

b)

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

c)

A minimum of two pressure gauges are required for the test

system. One pressure gage shall be on the test manifold and the
other(s) on the test system. Their accuracy shall be within 5% of
one another.

d)

When large systems are tested, Inspection personnel will determine

the need for additional gauges.

e)

Recording gauges shall be used where it is necessary to keep a

permanent record, e.g., when the test duration exceeds four hours,
or otherwise as required by this standard.

Expansion joints and spring hangers or spring supports shall be provided

with temporary restraints where needed to prevent excessive travel or
deformation under the test loads.

Equipment Excluded from Pressure Test

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 Saudi Aramco Inspector can be added:

7.3

a)

Rotating machinery, such as pumps, turbines and compressors;

b)

Strainers and filter elements;

c)

Pressure relieving devices, such as rupture disks and pressure relief valves;

d)

Locally mounted indicating pressure gauges, where the test pressure will
exceed their scale range;

e)

Equipment that cannot be drained;

f)

Instrument Devices.

Isolation of Test Sections

Paddle blinds or spectacle blinds shall be used to isolate the test sections. They
shall be the same class rating of the system or may be fabricated based on
appropriate calculations. When this is not practical, closed block valves (gate,
globe, plug, ball) may be used to isolate equipment or piping sections (provided
the valves are not passing, otherwise the spectacle plate/blind shall be installed
in the closed position). If closed block valves are used in lieu of blinds,

Page 12 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

provisions shall be made to ensure no overpressure can occur in the system that
is not being tested, due to possible leak through the valves.
When a block valve is used for isolating test sections, the differential pressure
across the valve seat shall not exceed the seat test pressure during pressure
testing and shall not exceed the rated seat pressure during tightness test. Both
sides of this valve shall be protected by relief valves during the test.
7.4

7.5

Vents and Drains

7.4.1

Vents shall be provided at all high points in the tested system as needed.

7.4.2

Excluding scrapable, submarine and buried pipelines, drains shall be

provided at all low points in the system and immediately above check
valves in vertical lines.

7.4.3

Unless the check valve has a by-pass valve, the disc of the check valve
shall be removed, and securely attached to the outside of the check valve
prior to the pressure test.

Temporary Connections and Supports

7.5.1

Temporary connections shall be provided for de-pressurizing and

draining of the system to the sewer or disposal area.

7.5.2

Temporary supports shall be installed prior to hydrostatic testing, and

flushing of the piping if they were determined to be required per SAESL-150. These supports shall not be removed until after the system has
been fully drained. The structural support system for stacked equipment
shall be verified for hydrostatic loads prior to testing.

Test Procedures
8.1

The test procedures shall be conducted in accordance with the applicable code.
In addition, the following requirements shall apply.
8.1.1

Filling and pressurizing shall be done on the upstream side of check

valves in the system. The test fluid shall be injected at the lowest point
in the system to minimize entrapped air. When filling at the lowest point
is not practical, the Inspection Department/ Operations Inspection
Engineering Unit shall be consulted. All vents shall be open during
filling.

8.1.2

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
Page 13 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

closed and the test pump disconnected. The isolation valve downstream
of the manifold shall be opened after the pump is disconnected.
8.1.3

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

8.2

All piping and equipment shall comply with the lay-up procedures per
SAES-A-007.

8.3

Test Records shall be recorded on Pressure Test Report Form 2642-ENG and the
applicable "Safety Instruction Sheet" per SAES-A-005.

After Completion of Pressure Test

After pressure testing has been successfully completed and approved by the Owner's
Inspector, the following operations shall be made.
9.1

Draining of Test Fluid

Release of pressure and draining shall be done on the downstream side of check
valves. All vents shall be opened before draining to facilitate drainage and to
prevent formation of a vacuum. No test fluid shall remain in low spots.

9.2

Disposal of Test Fluid

The test fluid shall be disposed in accordance with SAEP-327 or as directed by
the Owner.

9.3

Test Vents and Drains

Vents and drains used only for the pressure test shall be plugged, seal welded
and penetrant tested.

9.4

Removal and Reconnection of Components

All temporary items installed for testing purposes (e.g., manifolds, valves,
blinds, spacers, supports) shall be removed.
Items that were removed from testing shall be reinstalled.
Items, such as instrument air tubing, check valve discs which were disconnected
before testing shall be reconnected.
Isolation valves closed for the test purposes and that are required to be in the
open position for process reasons shall be opened. If the valve cavity has a
drain, the cavity shall be drained.

Page 14 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

30 March 2005

SAES-A-004
General Requirements for Pressure Testing

Revision Summary
Major revision.

Page 15 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

Appendix I Sample Form of Request for Non-Destructive Testing

In-Lieu of Hydrostatic Test
[ ] RT

[ ] MT

or

[ ] PT

BI/JO/WO: ____________________________________________________________

DATE: _____________

ORIGINATOR: _____________________________ LOCATION:______________________________________

TITLE _________________________________________
ORGANIZATION: __________________________

ADDRESS ______________________ PHONE _________

=======================================================================================
PRESENT SITUATION:

_______________________________________________________
_______________________________________________________
_______________________________________________________

JUSTIFICATION:
INSPECTION COMMENTS:
CONDITIONS OF APPROVAL:
REASONS FOR DISAPPROVAL:

CONCUR:

_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

______________________________________
RESPONSIBLE ENGRG. GROUP

(Note 3)

APPROVED BY

______________________________________, or
PLANT MANAGER

__________________________________
MANAGER, INSPECTION DEPARTMENT

NOTES:
1.

Attach sketch or drawing showing location of welds to be radiographed.

2.

Design information such as wall thickness, material, service conditions, operating pressure and temperature
shall also be included.

3.

The plant manager will sign the form for existing facilities and the Inspection Department Manager will sign for
new construction projects.

Page 16 of 17

Document Responsibility: Inspection Department

Issue Date: 30 March 2005
Next Planned Update: 1 April 2009

SAES-A-004
General Requirements for Pressure Testing

Appendix II Sample of SA 2642-ENG Pressure Test Report Form

SAUDI ARAMCO PRESSURE TEST REPORT
SAUDI ARAMCO 2642-ENG (03/05)
Reference Details:
Plant Name: ____________________________Plant No.: ___________BI No.: _______________ Project Name: _______________________
Responsible Inspection Unit: ______________ Equipment Description: _______________________ Location of Test: ___________________
System No.: _________________ Purchase/Work Order No.: ______________________ Letter/Diagram No.: _________________________
Verbal Report To: Name: _________________________ Position: _______________ Badge No.: ____________ Date: _____/______/______
Test Details: Initial Test Revalidation Test

Type:

Hydrostatic Test

Pneumatic Test

Pre Start-up Leak Test

Test Procedure No.: _________ In Accordance with: ___________ MAOP: ________PSIG MDMT: _________F Test Fluid Type: ________
Test Fluid Quality: pH: ____SRB: ____ Oxygen Scavenger: ______ Test Pressure: _______ Test Temperature: ____F Test Duration: _____
Relief Valve Test Date: _______/ ______ / ______

Relief Valve Set Pressure: __________PSIG

No. of Pressure Gauges: ____ Pressure Gauge Calibration Date: ______ / ______ / ______
Flushing/Cleaning: Method Used: ______________________________________________

Relief Valve Tag No.: ____________

Pressure Gauge Range: 0 to________PSIG

Accepted:

Rejected:

Inspectors Name: _____________________Signature: _______________________Badge No.: ____________ Date: ______/______/______

Lay-Up Procedure: None: Ambient Lay-Up: Wet Lay-Up: Dry Lay-Up: Other Method: ___________________
___________________________________________________________________________________________________________________
Sketch:

___________________________________________________________________________________________________________________
Pressure Test Results:
Accepted:
Rejected:
Inspectors Name: ______________________ Signature: _______________________ Badge No.: ____________ Date: ____/______/______
Field Supervisor Name: _________________ Signature: _______________________ Badge No.: ____________ Date: ____/______/______
Comments:
_________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________

Page 17 of 17