Saic A 2001

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SAUDI ARAMCO ID/PIEU-15-July-2018-REV. 2018.05.00(Standards Cutoff - May 31,2018) Rev.2018.05.

00 31-May-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

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

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

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

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

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

Procedure is project specific, identifiable by Budget Item (BI) or Job Sch Q,


A1 Number, Contract Number & Project title & traceable to Quality
Plan. Para 3.1, 3.2

A) An approval section exists to document adequacy prior to use.


Sch Q,
B) Revision
A2
control section exists to document procedure changes.
Para 3.1, 3.2
(ISO 9001:2008, Para. 4.2.3a)

An attachment section exists listing applicable QC forms & records. Sch Q,


A3 (ISO 9001:2008,
Para. 4.2.4a) Para 3.1, 3.2

Sch Q,
Other sections for special process control procedures (per Sch Q)
A4
detail references, responsibilities, definitions & procedure reqmts.
Para 3.1, 3.2

The data tracking system(s) shall be maintained and kept current


and available for Saudi Aramco's review at all times. Contractor
shall provide an electronic copy of production weld data in a native
file format which data can be filtered by different values such as SAEP-1160,
Welder ID., date, weld type, NDE, etc. The data shall be available Section5.2
A5
on a daily basis for both current data and cumulative data. Data
shall be retrievable by date for any given day from commencement
of the work through project completion. At the end of the project the
archived records shall be submitted in accordance with contract
requirements.

Saudi Aramco: Company General Use


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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-


Attachment 1 - Pressure Testing Matrix for On-Plot Piping (Incl. UG Utilities, FW & Plumbing)
ON-PLOT NEW B31.1 & B31.3 CODE PRESSURE PIPING (SATIP-A-004 Series)
SYSTEM TEST PRESS TEST CONSIDERATIONS & NOTES
&
Process As DURATION
Calculated* Piping Line Class List (Hydrotest Spec) lists all new process piping line classes (strength
30 mins (min) test required per code) with exceptions for Service Test and other tests as noted below. NDE in
Piping 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 See Notes *Lube & seal oil piping is pressure tested with its own fluid at 1.5 times design pressure or 100
30 mins (min) psig, whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be
Systems 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 As Calculated A) Test prior to backfilling (all joints exposed) & maintain test pressure for a minimum 2 hrs. B)
A) Process See Notes Per SAES-S-070, Section 18, Underground Utilities are tested for a minimum of 4 hours.
Piping If justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd.
B) Utility Piping
Flare Lines See Notes Flare lines 24-inch NPS & larger with a design pressure of 75 psig or lower may be strength
30 tested pneumatically (75 psig is tested at 1.1 factor or 82 psig) per Para. 345.5 of ASME B31.3
(24" & mins (min)
above)
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 See Notes Tested to 1.5 times the differential external pressure, but not less than 15 psig.
30
mins (min)
Air & Inert Gas SERVICE TEST & Perform a preliminary soap bubble test at 5-10 psig after construction is complete & threaded
(150 psig Soap Bubble Test joints are checked for engagement (two full visible thread rule). Coordinate with Compressor
max) 30 and Receiver Service tests and final gasket installation.
mins (min)
LP Steam SERVICE TEST Coordinate with system Service tests and construction completion.
(60 psig max) 30 mins (min)

Weld-Plus-Ends Soap Bubble Leak Weld-Plus-Ends shall be subjected to a pneumatic pressure test of 5 to 10 psig in the annulus
(SAIC- Test at 5-10 psig between the gasket and the seal weld. It shall be examined for leaks using a soap solution.
A-2016)
Existing Plant As Calculated* For revalidation purposes of existing plant piping, the test pressure shall be minimum required
Piping 30 mins (min) by the Code ASME B31.3. The actual wall thickness of the piping and flange rating shall be
Incl. Tie-Ins 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.

RETESTING See Notes Systems that already passed a successful pressure test require RETEST IF subjected to new
REQMTS 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 See Notes Every existing plant piping & pipeline, after repairs or alterations have been made that affect the
EXISTING integrity of the pressure containing parts, shall successfully pass a hydrostatic test. The test
PIPING 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 EXEMPT, Drains, vents & piping downstream of pressure relieving devices that discharge directly to the
Piping VISUAL EXAM 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 As Calculated* Whether piping or tubing, between the root isolation valve and the instrument isolation shall be
Impulse Lines 30 mins (min) 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. When 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).

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-


Internally FBE As Calculated* For internally Fusion Bonded Epoxy (FBE) coated piping system, the test pressure shall not
Coated Lines 30 mins (min) 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.
Sampling Lines See Note Test as an integral part with the piping or equipment to which it is connected.
Vessel & Tank See Note Test separately (separate package) as required. Exemptions include sight glasses
Trim & other instruments. Strength or Service test associated piping based on service
(Piping)
Note: ALL Code Piping construction (in-situ) that is not VENDOR supplied shall be tested. Utility = Service Test, Process = Strength Test
Skid-Mounted EXEMPT IF TESTED BY 1. When testing with adjacent Lube oil system piping (no leaks = acceptance).
Piping (Vendor) VENDOR per 01-SAMSS-010 2. When code repairs are made to skid-mounted piping to correct
misalignment, physical damage or any modifications in-situ, pressure test the
(exceptions noted) affected spools.
FIELD HYDROTESTING OF NEW VALVES (SAES-L-108, Section 4.7 & SATIP-L-108 & SAIC-L-2042)
Test Location See Note Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Field Testing of See Note 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.
New Valves
Exception 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 See Note Buttweld & socketweld end valves in NPS 2 inches and smaller are exempt
Procedure See Note Test procedures, pressures, durations, & leakage acceptance criteria shall be
equal to those that the valves were originally purchased to. All resilient (soft)
(Checklist Item D4)
seated isolation valves shall have zero leakage. See SAIC-L-2042
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 REQUIREMENT 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 SAES-K-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 in 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.

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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-


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.

Saudi Aramco: Company General Use


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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 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 for service at the design pressure.

Tightness Test: Pressure test to ensure piping system tightness (i.e., no


system leaks) at test pressure.
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 atmosphere 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
target at exit. Air Shock Blowing (PASB): Use PASB for initial cleaning for instrument air, plant air and as an
Pressurized
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 verify 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 flushed 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 corrosion. 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.

Saudi Aramco: Company General Use


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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-


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
TEST WITH CSDISOLATION
approved corrosion
AGAINSTprevention
VALVE SEATS measures.
(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 =
flange)
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 (Refer 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
Resolution: time valve
Remove for seat test.
from Refer
line to API
for test, 598aTable
install 150# 4.blind
Closure test
flange &= 1 minute
proceed (valves
with test atto450
12”psi
NPS)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
Company approval
between is required)
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
LIMITING30 minute
FACTOR hydro
CALCSat 450 psi. Isolation
(PREVENT valve is a Higher Class
OVERPRESSURIZATION (No seat 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)
Example #1: A CS 150 # Raw Water System 12LEOU (hydrotest at 450 psi per SIS, limiting factor = flange)
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 three open gate valves, one check valve (internals removed for test), and one closed

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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-


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 ratings 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
Formula
seat). for pressure isB)P Request
= t x 2S(0.9)(E) /D
a test pressure reduction to 400 psig and test limit revision & proceed with
S = Stress
review, evenValues
after 2from ASME B31.3 Table A-1 (API 5L Gr. B has a SMYS of 35,000) therefore S = 35,000
errors.
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.

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Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 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 WINDOW 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.

Saudi Aramco: Company General Use


SAUDI ARAMCO ID/PIEU-15-July-2018-REV. 2018.05.00(Standards Cutoff - May 31,2018) Rev.2018.05.00 31-May-18

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-

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

Saudi Aramco: Company General Use


SAUDI ARAMCO ID/PIEU-15-July-2018-REV. 2018.05.00(Standards Cutoff - May 31,2018) Rev.2018.05.00 31-May-18

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Pressure Testing (All Applications) SAIC-A-2001 15-Jul-18 MECH-

Saudi Aramco: Company General Use

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