Professional Documents
Culture Documents
Rev 4
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
REV. NO.
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
EQPT CODE
SYSTEM ID.
PLANT NO.
MH's SPENT
TRAVEL TIME
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
PASS
FAIL
N/A
Special Process Procedure Elements (Typical for "REVIEW PROCEDURE" type Special Process SAICs, See Notes)
A1
Sch Q,
Para 3.1
A2
Sch Q,
Para 3.1
A3
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
SAEP-1160,
Section 6
(Data Elements)
Page 1 of 20
RE-INSP DATE
Rev 4
ITEM
No.
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
REFERENCE
31-Mar-10
DATE APPROVED
31-Aug-11
PASS
FAIL
General Requirements
Note 1: Use SAIC-A-2003 for specific Test package responsibilities & instructions
Note 2: Use SAIC-A-2009 for specific Testing Equipment requirements including Safety Inspections
B1
B2
GI-2.102
Para 5.1.2.5
B3
GI-002.102,
Attachment 1,
Section 5
See Note 2 &
SAIC-A-2009
B4
SAES-A-004,
Section 5.7
Page 2 of 20
MECH-
CONTRACTOR / SUBCONTRACTOR
SAEP-1160,
Section 8
See Note 1 &
SAIC-A-2003
QR NUMBER
N/A
RE-INSP DATE
Rev 4
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
B5
SAES-A-007,
Para 4.3.1
B6
SAES-L-150,
Section 4
See also
Attachment 2
C1
SAES-L-150,
Section 8
C2
SAES-L-150,
Section 8
C3
SAES-L-150,
Section 8
C4
On-Plot Piping Pressure Testing (Includes all Utilities, Firewater & Plbg References, SAIC-S-Checklists & SATRs)
Page 3 of 20
PASS
FAIL
N/A
SAES-L-150,
Section 5 Para
5.11
RE-INSP DATE
Rev 4
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
D1
Define Test
Workscope
& Specifications
Sch Q, Att IV,
Table 2.1
D2
SAES-L-150,
Section 5.3
D3
SAES-L-150,
Section 5.11
& SAES-L-108,
Section 4.7
D4
SAES-L-150,
Section 5
D5
Lube and seal oil piping is strength tested in its own fluid at the greater
of 1.5 times design pressure or 100 psig (for 30 minutes).
SAES-L-150,
Section 7
Para 7.5.1
D6
SAES-L-150,
Section 7.5.2
D7
Page 4 of 20
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
Rev 4
ITEM
No.
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
REFERENCE
D8
SAES-L-150,
Section 5
D9
SAES-L-150,
Para 5.12
D10
SAES-L-150,
Section 5.8
D11
SAES-L-150,
Section 5.9
D12
SAES-S-060,
Para. 103.5.3.3
Page 5 of 20
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
Rev 4
ITEM
No.
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
REFERENCE
D13
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 & joints accessible) with air, CO2, or
nitrogen (Oxygen prohibited) at test pressure not less than 1- times
maximum working pressure, but not less than 60 psi (413kPa) for a
SAES-S-060,
period of not less than thirty (30) minutes.
Para. 103.5.3.3,
C) A low pressure air test not exceeding 345 kPa (50 psig), & soap
Para 1204.3.2,
bubble test shall be used to test sanitary drainage or plumbing system of
Para. 103.5.5.1
any building premises when there is reason to believe that it has become
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.
D14
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 & joints accessible) with air, CO2, or
nitrogen (Oxygen prohibited) at test pressure not less than 1- times
maximum working pressure, but not less than 60 psi (413kPa) for a
SAES-S-060,
period of not less than thirty (30) minutes.
Para. 103.5.3.3,
C) A low pressure air test not exceeding 345 kPa (50 psig), & soap
Para 1204.3.2,
bubble test shall be used to test sanitary drainage or plumbing system of
Para. 103.5.5.1
any building premises when there is reason to believe that it has become
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.
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
Service Test, Leak Test, Minor Repair & Other Applications (Include & detail Service Test limitations per scope)
E1
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).
Vessel Trim & Sampling lines also receive a Service test.
SAES-L-150,
Section 9.3
E2
SAES-L-150,
Section 9.1
Page 6 of 20
RE-INSP DATE
Rev 4
ITEM
No.
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
31-Mar-10
DATE APPROVED
REFERENCE
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).
SAES-L-150,
Section 9.2
E4
SAES-L-150,
Section 7.6
31-Aug-11
PASS
FAIL
F1
Procedure* & Design Package* for Hot Taps & Stoppling Connection
Install.
Note:
* Use latest Edition SAEP-311 (Safety).
F2
F3
F4
Cleaning, Flushing, Water Treatment & Lay-up (Include applicable requirements into the procedure)
G1
SAES-L-350,
Section 15
G2
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 10 per ml is unacceptable. Treat test fluid to
control corrosion and bacteria when applicable.
Employ regular water analysis, maintain certs and records.
SAES-A-007
Section 4
Page 7 of 20
Use
SAIC-L-2090
SAICL-2091
Use
SAICL-2095
Use
MECH-
CONTRACTOR / SUBCONTRACTOR
Use
QR NUMBER
SAICL-2095
N/A
RE-INSP DATE
Rev 4
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
G3
Test Procedure details Lay-up & treatment of Hydrostatic Test Water 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 CSD approved
Procedure can utilize SAES-A-007, Section 5 in entirety
SAES-A-007
Para 5.2
G4
Test Procedure details Lay-up & treatment of Hydrostatic Test Water 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
Procedure can utilize SAES-A-007, Section 6 in entirety
SAES-A-007
Section 6
G5
SAES-A-007
Section 7
H1
SAES-A-004,
Section 5.6
H2
Test manifolds are certified & tested to 1.2 times maximum test pressure
but not less than discharge pressure of test pump.
Manifold Test Report (Sketch & Certificate) is required. The sketch
lists detailed information/ratings of all components. Manifolds
receive unique numbers and records are kept.
SAES-A-004
Para 5.5.4
H3
SAES-A-004,
Para 8.3
Page 8 of 20
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
Rev 4
ITEM
No.
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
REFERENCE
H4
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.
Inspectors check valve lineup & position prior to testing.
SAES-A-004,
Para. 9.1.3
H5
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)
SAES-A-004,
Para 8.3 &
Attachment 2
H6
SAES-L-150,
Section 7.1
Attachment 2
H7
SAES-A-004
Para 8.1.4
H8
SAES-A-004
Para 8.2
H9
SAES-L-150,
Section 6
H10
SAES-A-004
Para 5.5.1
H11
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 ID Manager & Proponent
SAES-L-150,
Section 7.3
Page 9 of 20
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
Rev 4
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ITEM
No.
ACCEPTANCE CRITERIA
REFERENCE
H12
Test duration and hold times consider full inspection access via
scaffolding & manlifts as necessary to allow visual inspection of 100% of
all joints including weep holes, 6mm drain holes in dummy legs
(required). Inspection time may exceed test times listed in SIS sheets &
Hydrotest reports (30 minute is a minimum).
Inspectors shall complete inspection before tests are ended.
SAES-L-150,
Para. 7.2
H13
SAES-L-150,
Section 6
H14
SAES-A-004
Para 9.1.1
H15
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".
Test water reuse is restricted to ensure cleanliness & quality
SAES-L-150,
Section 11
H16
SAES-A-004,
Para. 9.1.2
H17
SAES-A-004
Para 8.1.5
H18
SAES-A-004,
Section 6
as referenced
Page 10 of 20
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
Rev 4
ITEM
No.
SAIC NUMBER
SAIC-A-2001
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
REFERENCE
I1
SAES-L-310,
Section 22
I2
SAES-L-310,
Section 22
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
REMARKS:
Pressure Test Procedure (SAES-A-004 Definition): Information assembled to ensure all requirements listed in GI-0002.102 , all referenced
SA & Industrial standards are met. Per SAES-A-004 Definition, test packages are part of the Pressure Test Procedure. This checklist
Note provides a complete detailing of all Pressure Testing Applications/Requirements for SA Projects. See Attachment 1.
1
Hydrotest, Pneumatic and Soap Bubble Leak Test*, Service Test, & Valve Testing, can be one (1) procedure (Pressure Testing). Small
projects (less than 500 welds) do not require a Database for tracking welds & test packages per SAEP-1160 requirements.
*Note: Soap Bubble Leak Test procedure (See SAIC-A-2005) shall meet ASME SEC V Article 10 & Appendix requirements.
Pressure Test Plan is submitted for Company review & contains the following 4 elements necessary to control the work:
1. Pressure Test Procedure (Including Test Package Controls)
Note 2. Sample Hydrotest Package Per SAIC-2003
2
Hydrotest Data Mgmt & Tracking Database per SAEP-1160
Small projects (less than 500 welds) do not require a Database for tracking welds & test packages per SAEP-1160 requirements.
4. Pressure Testing Specification (Plant Piping 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 SA Standards 3) Ultimate Customer Satisfaction 4) Cost Savings through Quality.
This section is
4
not repeated in other "Review Procedure" type special process checklists, yet is intended for all.
ATTACHMENTS: Attachment 1 - Pressure Testing Matrix for SA Projects
Attachment 2 - Pressure Testing Inspection Guide
REFERENCE DOCUMENTS:
Page 11 of 20
Rev 4
SAIC NUMBER
SAIC-A-2001
PROJECT TITLE
ITEM
No.
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
31-Mar-10
DATE APPROVED
REFERENCE
QR NUMBER
31-Aug-11
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
1.
Contract Schedule Q - Quality Assurance and Control, Inspection and Testing (Project Specific)
2.
SA General Instruction Manual GI-002.102 (28 October 2008) Pressure Testing Safely
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
SAEP-1160 (2 Augest 2009) Tracking & Reporting of Welding, NDT & Pressure Testing for Capital Projects
SAES-A-004 (14 December 2009) General Requirements for Pressure Testing
SAES-A-007 (3 July 2007) Hydrostatic Testing Fluids and Lay-Up Procedures
SAES-L-108 (21 March 2010) Selection of Valves
SAES-L-150 (1 November 2008) Pressure Testing of Plant Piping and Pipelines
SAES-L-310 (29 April 2007) Design of Plant Piping
SAES-L-350 (22 April 2009) Construction of Plant Piping
SAES-S-010 (21 November 2009) Sanitary Sewers
SAES-S-020 (24 January 2010) Industrial Drainage and Sewers
SAES-S-030 (5 July 2009) Storm Water Drainage Systems
SAES-S-040 (31 December 2003) Saudi Aramco Water Systems
SAES-S-050 (27 January 2007) Sprinkler and Standpipe Systems in Buildings
SAES-S-060 (28 January 2004) Saudi Aramco Plumbing Code
SAES-S-070 (13 Novemebr 2007) Installation of Utility Piping Systems
SAEP-311 (13 September 2009) Installation of Hot Tapped and Stopple Connections (Use Latest Edition for Safety)
Contractor / Third-Party
RE-INSP DATE
Saudi Aramco
Construction Representative*
PMT Representative
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
PID Representative
Performed Inspection
QC Supervisor
Name, Organization,
Initials and Date:
Y = YES
Page 12 of 20
N = NO F = FAILED
Rev 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
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 piping is pressure tested with its own fluid at 1.5 times design pressure or 100 psig,
See Notes
Lube & Seal Oil
whichever is greater. Chemical cleaning precedes pressure testing. Joints shall be completely
30 mins (min)
Systems
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
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
justifiable (safety, back-filled line) a 24 hr recorded test (Chart Recorder) is reqd.
Flare Lines
(24" & above)
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.
Tested to 1.5 times the differential external pressure, but not less than 15 psig.
Vacuum Piping
See Notes
30 mins (min)
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.
Weld-Plus-Ends
(SAIC-A-2016)
Existing Plant
Piping
Incl. Tie-Ins
RETESTING
REQMTS
See Notes
LP Steam
(60 psig max)
As Calculated*
30 mins (min)
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
As Calculated*
30 mins (min)
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. 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).
Internally FBE
Coated Lines
As Calculated*
30 mins (min)
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 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
QR NUMBER
31-Aug-11
MECH-
Sampling Lines
See Note
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 made 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)
See Note
Location shall be specified by proponent & PID approved. SAIC-A-2031 Sect. J
Test Location
All new valves designated for isolation service (as specified by the Proponent) shall be
See Note
Field Testing of
subjected to high pressure hydrostatic seat test prior to installation in line.
New Valves
Low pressure pneumatic seat test at 5 psig shall be substituted for high pressure
See Note
Exception
hydrostatic seat test for flare system valves. Identify & Segregate Early!!!
Exemption
Procedure
(Checklist Item D4)
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
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.
Page 14 of 20
Rev 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
31-Aug-11
QR NUMBER
MECH-
Rev 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
31-Aug-11
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 = 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 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 listed (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 = 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 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 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 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 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
31-Aug-11
QR NUMBER
MECH-
Page 17 of 20
Rev 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
31-Aug-11
QR NUMBER
MECH-
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.
Page 18 of 20
Rev 4
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
31-Aug-11
QR NUMBER
MECH-
OVER PRESSURIZATION ALERT FOR LATERALS (60 Degree Lateral Branch Code Calc Example)
Page 19 of 20
Rev 4
Page 20 of 20
SAIC NUMBER
SAIC-A-2001
31-Mar-10
DATE APPROVED
31-Aug-11
QR NUMBER
MECH-