SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.

00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Pressure Testing Safely GI-2102 30-Apr-17
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.
PROCEDURE
G.I. 0002.102
1 Is a written, approved procedure available at the job site? para. 2.0 (a)
G.I. 0002.102
2 Has the procedure has been approved by the appropriate authority? para. 5.1
G.I. 0002.102
3 Is a pressure test or hydrostatic test diagram included with the procedure? para. 5.1
Has the test manifold arrangement been included in the pressure test or G.I. 0002.102
4
hydrostatic test diagram? para. 5.1
G.I. 0002.102
5 Has the location of all blind flanges and isolation valves been included? para. 5.1
Has the location of all check valves (flappers to be removed, if necessary) been G.I. 0002.102
6
included? para. 5.1
G.I. 0002.102
7 Has the location of lowest rated component been included? para. 5.1
G.I. 0002.102
8 Has the location of the air vents been included para. 5.1
G.I. 0002.102
9 Is the relief valve size and set pressure included? para. 5.1
G.I. 0002.102
10 Is the vacuum valve size and set pressure included? para. 5.1
G.I. 0002.102
11 Has the type of test medium be included? para. 5.1
G.I. 0002.102
12 Are the test pressures (Strength and Tightness, if necessary) indicated? para. 5.1
G.I. 0002.102
13 Has the need for any special supports been identified? para. 5.1
G.I. 0002.102
14 Has the need for chemical additives been addressed? para. 5.1
G.I. 0002.102
15 Has the test sequence been correctly identified? para. 5.1
G.I. 0002.102
16 Has the minimum temperature at which the test can take place be established? para. 5.1
G.I. 0002.102
17 Have the inspection requirements been established? para. 5.1
G.I. 0002.102
18 Have the areas to be kept free of people during test been properly identified? para. 5.1
G.I. 0002.102
19 Are the locations of the barricades identified? para. 5.1
G.I. 0002.102
20 Are the locations of warning signs and markings for test area identified? para. 5.1
G.I. 0002.102
21 Have the work permit requirements been addressed? para. 5.1
G.I. 0002.102
22 Has test medium disposal been appropriately addressed and approved? para. 5.1
G.I. 0002.102
23 Are additional or special of personnel safety requirements required? para. 5.1
G.I. 0002.102
24 Are the Safety Instruction Sheet (SIS) available? para. 5.1
G.I. 0002.102
25 Will emergency communication be required and what are the methods? para. 5.1
ASSIGN RESPONSIBILITY
Has responsibility for the test has been assigned e.g Hydrostatic Test Coordinator G.I. 0002.102
26
and Safety Coordinator? para. 5.1

For major test, have representatives from Inspection, proponent Organization and G.I. 0002.102
27
Loss Prevention have been notified? para. 5.1

G.I. 0002.102
28 Is water the test medium? para. 5.3

G.I. 0002.102
29 If not is use of a test medium other than water justified? para. 5.3

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Pressure Testing Safely GI-2102 30-Apr-17
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM ACCEPTANCE CRITERIA REFERENCE ACCEPT REJECT N/A RE-INSP DATE

TEST MEDIUM
When water is not the test medium, Have the appropriate precautions been taken G.I. 0002.102
30
to prevent hazardous conditions? para. 5.1.3

Have test personnel been provide with the appropriate safety equipment to protest G.I. 0002.102
31
from test mediums other than water? para. 5.1.3

Has a test medium disposal procedure been developed with the Environmental G.I. 0002.102
32
Engineering Division. para. 5.1.3

SELECTION and TREATMENT of HYDROSTATIC TEST WATER

Has SAES-A-007 been followed for the selection and treatment of hydrostatic test G.I. 0002.102
33
water? para. 5.1.4

TEST EQUIPMENT (minimum requirements as follows)

Is a relief valve which has been calibrate within the past 7 days and tagged G.I. 0002.102
34
"TEST", with the set pressure and date been provided? para. 5.1.5

G.I. 0002.102
35 Has it been verified that no block valve is in the relief valve outlet? para. 5.1.5
G.I. 0002.102
36 Has it been verified that no block valve is in the relief valve inlet? para. 5.1.5

Is a relief valve located in the system under test and near the test pump or other G.I. 0002.102
37
test medium supply? para. 5.1.5

Have two or more accurate and reliable pressure gages of proper range, calibrated G.I. 0002.102
38
within the last 30 day of the pressure test been provided? para. 5.1.5
G.I. 0002.102
39 Have the pressure gages been provided with block and bleed valves? para. 5.1.5
G.I. 0002.102
40 Have the pressure gages been properly located within the system to be tested? para. 5.1.5
Can the pressure gage located at the test pump or test medium supply be read by G.I. 0002.102
41
the pump operator? para. 5.1.5
G.I. 0002.102
42 Is a blow down valve available on the piping under test? para. 5.1.5
Is the blow down valve readily accessible and piped or draining to a designated G.I. 0002.102
43
location, drain or area? para. 5.1.5
G.I. 0002.102
44 Is an isolation valve available on the piping under test? para. 5.1.5
Has the test manifold and all related test piping been pre-tested to a minimum of G.I. 0002.102
45
20% above the test pressure of the system to be tested. para. 5.1.5
Was the test of the test manifold and all related test piping been properly G.I. 0002.102
46
documented and witnessed? para. 5.1.5
WORK PERMITS
G.I. 0002.102
47 Has the necessary work permit been obtained? para. 5.1.6
G.I. 0002.102
48 Is a "Cold Work" permit required? para. 5.1.6
G.I. 0002.102
49 Is a "Hot Work" permit required? para. 5.1.6
G.I. 0002.102
50 Is a "Confined Space" permit required? para. 5.1.6
G.I. 0002.102
51 Is a "Release of Hazardous Materials" permit required? para. 5.1.6
ISOLATE EQUIPMENT NOT ADEQUATE FOR TEST PRESSURE
G.I. 0002.102
52 Have appurtenances that are not part of the test properly isolated prior to the test? para. 5.1.7
Have provisions been made to ensure that no overpressure can occur in G.I. 0002.102
53
equipment that is not being tested? para. 5.1.7
PREVENT OVERLOADS FROM WEIGHT OF LIQUID
G.I. 0002.102
54 Will the weight of the test liquid overload the system under test? para. 5.1.8

G.I. 0002.102
55 Have temporary supports or other means been provided to prevent overloads? para. 5.1.8

SAFE CHEMICAL HANDLING

Have testing personnel been provide all the appropriate personal safety equipment G.I. 0002.102
56
required when required to handle chemicals? para. 5.1.9

BRITTLE FRACTURE
Is the temperature of the test medium above the temperature at which the impact G.I. 0002.102
57
requirements are met by the material to avoid brittle fracture? para. 5.1.9

ACCESS CONTROL TO SITE

In plants and shops have the test areas been properly marked and warning signs G.I. 0002.102
58 para.
posted to alert approaching personnel? 5.1.11/5.18

Have additional personnel been post at the plant site to keep the test area clear of G.I. 0002.102
59 para.
all people not connected with the test? 5.1.11/5.18

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Pressure Testing Safely GI-2102 30-Apr-17
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

For system outside of the plant, have warning signs been placed at locations G.I. 0002.102
60 para.
where people could be exposed. 5.1.11/5.18

ITEM ACCEPTANCE CRITERIA REFERENCE ACCEPT REJECT N/A RE-INSP DATE

For pipelines crossing underneath a road, has traffic been diverted or stopped G.I. 0002.102
61 para.
during the test or personnel posted? 5.1.11/5.18

For above ground pipelines parallel to a road within 30m (100ft), has the traffic G.I. 0002.102
62 para.
been diverted or stopped during the test or a waiver signed. 5.1.11/5.18

NOTIFY ARAMCO AFFAIRS OF NON-SAUDI ARAMCO EXPOSURE

Has Saudi Aramco Affairs been notified if non-Saudi Aramco facilities will be G.I. 0002.102
63
exposed during the pressure test of Saudi Aramco facilities? para. 5.1.12

64 TRAFFIC CONTROL
When traffic control is required has the Saudi Aramco Industrial Security G.I. 0002.102
65
Department been notified? para. 5.1.13
PUBLICIZE TEST INTERFERING WITH TRAFFIC
Have test which will interfere with traffic been publicized in the Saudi Aramco
G.I. 0002.102
66 Highlights and Notices? Note The time of the test shall not occur during peak para. 5.1.14
hours.

DURING TEST REQUIREMENTS

BEFORE PRESSURIZING
G.I. 0002.102
67 Have all high point vents been opened while the system is being filled? para. 5.2.2
G.I. 0002.102
68 Have all the vents been closed after the air in the system has been removed? para. 5.2.2

Has the temperature of the test medium been permitted to equalize with the G.I. 0002.102
69
outside environment prior to pressurizing? para. 5.2.8

CONTROL OF PRESSURE RISE

Is the pressure being increased gradually with at least 10 minute holds at each G.I. 0002.102
70
step in the strength test? para. 5.2.3.2

Is the system inspected for leaks or required repairs before exceeding the 50
percent of the strength test pressure for tests using liquid or 173 kPa (25psi)/50 G.I. 0002.102
71
percent of the strength test pressure, whichever is the smaller, for any test using para. 5.2.3.2
air or other gas as the test medium?

For strength test using air or other gas, is the pressure increased in steps no
G.I. 0002.102
72 greater than one-tenth of the strength test pressure after reaching 50 percent of para. 5.2.3.3
the test pressure?

In strength test using liquid, is the pressure increased in steps no greater than one- G.I. 0002.102
73
fifth of the test pressure after reaching 50 percent of the test pressure? para. 5.2.3.4

G.I. 0002.102
74 Has the test pump been left unattended during the pressure testing? para. 5.2.8

DEPRESSURIZATION BEFORE STOPPING LEAKS OR REPAIRING

When leaks are located or repairs required is the pressure on the system released G.I 0002.102
75
prior to taking corrective action? This includes tightening of bolts. para. 5.2.4

POST TEST REQUIREMENTS

SAFE DEPRESSURIZATION
Was the system depressurized though the use of a depressurization valve?
G.I. 0002.102
76 Depressurization may not be accomplished by loosening bolts and or unscrewing para. 5.2.6
fittings.

G.I. 0002.102
77 Is the depressurization valve and associated piping arranged for safe discharge? para. 5.2.6

G.I. 0002.102
78 Is the system depressurized at a slow enough rate to prevent damage? para. 5.2.6

Have heat exchangers been monitored with pressure gages if necessary to G.I. 0002.102
79
prevent excessive differential pressures? para. 5.2.6

G.I. 0002.102
80 Ensure that the relief valve is only removed after complete draining of the system. para. 5.2.8

TEST MEDIUM DISPOSAL

Have the requirements of the test medium disposal procedure been correctly G.I. 0002.102
81
implemented? para. 5.2.7

Saudi Aramco: Company General Use