Inspection Procedure

00-SAIP-06 31 August, 2004

Pressure Test Requirements
Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 References..................................................... 2
3 Pressure Test Requirements......................... 3
4 Special Test................................................... 3
5 Reporting Methods......................................... 4

Previous Issue: 31 December, 2000 Next Planned Update: 1 September, 2009

Revised paragraphs are indicated in the right margin Page 1 of 4
Primary contact: Nasser M. Balhareth on 874-6604

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Department 00-SAIP-06
Issue Date: 31 August, 2004
Next Planned Update: 1 September, 2009 Pressure Test Requirements

1 Scope

1.1 This SAIP is to highlight certain pressure test requirements, identify special
tests, explain reporting methods and to provide instructions for witnessing
pressure tests on new or existing equipment and piping.

1.2 This SAIP does not include pressure test requirements for the following:
Construction of On-Land and Near Shore Pipelines SAES-L-450
Installation of Freon Refrigeration System SAES-K-xxx Series
Plumbing Installations UPC
Hot Tap Connections SAES-L-052
Thermoplastic Pipe SAES-S-xxx Series
Reinforced Thermosetting Resin Pipe SAES-S-xxx Series
Bottled Gas Cylinders BGM (Bottled Gas Manual)

2 References

The following standards were used in the preparation of this procedure and should be
carefully reviewed by the inspector prior to witnessing pressure tests:

Saudi Aramco References

Saudi Aramco Engineering Standards

SAES-A-004 Pressure Testing
SAES-A-005 Applicable Safety Instruction Sheets
SAES-A-007 Hydrostatic Test Fluids and Required Lay-ups
SAES-B-017 Fire Water Systems
SAES-L-150 Pressure Testing of Plant Piping and Pipelines

General Instruction
GI-0002.102 Pressure Testing Safely

Saudi Aramco Forms

SA 2093-ENG Equipment Inspection Record-General
SA 2642-ENG Pressure Test Report
SA 2642-1-ENG Pressure Test Information Sheet

Page 2 of 4

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Department 00-SAIP-06
Issue Date: 31 August, 2004
Next Planned Update: 1 September, 2009 Pressure Test Requirements

3 Pressure Test Requirements

3.1 Both Relief and Bleed Valves are required for all piping and equipment under
test. (SAES-A-004 para. 5.5)

3.2 The inspector shall witness and accept the flushing procedures prior to
commencement of pressure test. (SAES-A-004, para. 7.1.2)

3.3 Filling and Draining of the system under test shall be performed carefully to
prevent entrapped air or formation of a vacuum. (SAES-A-004, para. 8 and 9)

3.4 Firewater Systems shall be tested for 4 hours in accordance with SAES-B-017.

3.5 Pressure Sewers shall be tested under the same conditions as for pressure piping.

3.6 Buried lines should be tested before backfilling. In cases where a trench has
been backfilled prior to a pressure test, a 24-hours pressure/temperature
recorded test is required per SAES-L-150.

3.7 Welded connections that are impractical to pressure test may be 100% inspected
by NDE in lieu of a pressure test (SAES-A-004, para. 5.6.2). The Appendix of
SAES-A-004 shall be used for reporting and approving NDE in lieu of pressure
test. This sheet should be submitted to the applicable approval authority at least
24 hours prior to the actual test.

3.8 Safety requirements described in SAES-A-004 shall be reviewed and closely

followed when pressure testing.

3.9 Hydrostatic test diagrams and procedures shall be provided by the operations
engineering groups within an operating plant or the contractor for new projects,
to the inspector prior to conducting the test. Refer to SAES-A-004, para. 5.6.1
for details of these documents.

3.10 The pressure test manifold shall be separately tested at 1.2 times the system test
pressure prior to the actual system pressure test. (SAES-A-004, para. 6.5.4)

4 Special Test

Pneumatic and Inert Gas test procedures shall be submitted and approved prior to
testing by the Manager, Inspection Department except where allowed by SAES-A-004
and SAES-L-150. Loss Prevention shall also approve the pneumatic test procedures
when air is used and the equipment has previously been in flammable service. Refer to
SAES-A-004, para. 5.2.

Page 3 of 4

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Department 00-SAIP-06
Issue Date: 31 August, 2004
Next Planned Update: 1 September, 2009 Pressure Test Requirements

5 Reporting Methods

5.1 The Pressure Test Information sheet (Form 2642-1-ENG) shall be completed by
the assigned inspector for each pressure test.

5.2 The Appendix of SAES-A-004 shall be completed and approved for all NDE in
lieu of pressure test as described above in para. 4.7.

5.3 Permanent recording of pressure test results shall be made on the Pressure Test
Report (Form 2642-ENG).

5.3.1 A copy of the Pressure Test Report shall be sent to the Construction
agency on new projects.

5.3.2 Records should also be entered in the Equipment Inspection Record,

General (Form 2093-ENG). Both forms will go into the plant record
books for either turn-over to Operations Inspection or for the plant
record books after a test is conducted by the Operations Inspection
personnel.

Revision Summary
31 August, 2004 Revised the "Next Planned Update". Insure the contents of the document, delete items
number (2) "Purpose", updated referenced documents and done editorial changes.

Page 4 of 4

Copyright©Saudi Aramco 2009. All rights reserved.