00 ZA E 02018 Att2B-Test Pack Contents 00A

Client: Job. No 315900

SAUDI ARAMCO Date :

Unit :

KHURAIS (SAUDI ARABIA) TP No. :

System No. :

KHURAIS CRUDE CONTRACT(SATR-W-2008)

WELD SUMMARY, WELDER PERFORMANCE & SPECIAL PROCESS (NDE, etc) TRACKING SYSTEM

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PREPARED BY: VERIFIED BY: REVIEWED AND APPROVED BY: REVIEWED BY:

CONSTRUCTION REPRESENTITIVE QC SUPERVISOR OR INSPECTOR MAIN CONTRACTOR OR LSTK QA REPRESENTITIVE PID REPRESENTITIVE

NAME: NAME: NAME: NAME:

SIGN: SIGN: SIGN: SIGN:

DATE: DATE: DATE: DATE:

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FILM QUALITY

WELDQUALITY


SAUDI ARAMCO Date :

Unit : KHURAIS (SAUDI ARABIA) TP No. :

System No. : KHURAIS CRUDE CONTRACT

Service/Pipe Class Percentage RT Report

As per BE-653843

Location:

Project:


SAUDI ARAMCO Date :



VALVE TEST REPORT

MDT.TB.CDQ.0116

TAG/ITEM ENGINEERING DOCUMENT n. SUPPLIER DOCUMENT n. CODE/SPECIFICATION

IDENTIFICATION OF MONITORING AND MEASURING DEVICES:

DATE: MANUFACTURER:

TYPE VALVE

Size Class (Rating)

Trim Material Tag No. / Symbol

Body Material ID No.

For Cast Steel Valves OnlyBody Heat # Bonnet Heat #

PRESSURE TESTValve Body Hydro Test

Test Duration:………..[min] Test Pressure …………………. Pass Fail

Test Duration:………..[min] Test Pressure …………………. Pass Fail

Upstream Valve Seat Downstream Valve Seat

Low Pressure Test___________________ PSIG_______ Leakage Rate. __________# Drops, Bubbles/Minute

Pass Fail

High Pressure Test__________________ PSIG_______ Leakage Rate __________# Drops, Bubbles/Minute

Pass Fail

Test Duration___________ Minutes

Test Result Accepted Rejected

NOTES

RFI No.

PREPARED BY: ISSUE DATE:

QC SNAMPROGETTI CLIENT

SIGNATURE SIGNATURE SIGNATURE SIGNATURE

Date Date Date Date

Location:

Project:

PAGE OF

Gate Globe Ball Check Butterfly

Retest

If rejected, see MER/NCR # _____

INSPECTION NOTIFICATION REFERENCE

NAME NAME NAME NAME


SAUDI ARAMCO Date :



Flange Joint Inspection Report

MDT.TB.CDQ.0106


PAGE OF

BOLTS TIGHTENING

-1 Removed Checked by date Installed Checked by date Completed Checked by date

NOTES

INSPECTION NOTIFICATION REFERENCE

RFI No.

PREPARED BY:ISSUE DATE:

QC SNAMPROGETTI COMPANY


Date Date Date Date

Location:

Project:

IDENTIFICATION OF MONITORING AND MEASURING DEVICES:

JOINT REF.N°

PIPING ISOMETRIC REF.DWG.N

°

REMOVAL OF TEMPORARY GASKETS

INSTALLATION OF FINAL GASKETS

Notes: 1-Construction Contractor shall identify on QA/QC copy of piping isometric dwgs. the joint reference number using an alfa numeric code, copy of this isometric shall be attached

NAME NAME NAME NAME


SAUDI ARAMCO Date :



VISUAL CHECKS OF ORIFICE FLANGES

MDT.TB.CDQ.0105


IDENTIFICATION OF MONITORING AND MEASURING DEVICES

SKETCH N. / LINE N.

NOTESINSPECTION NOTIFICATION REFERENCE

RFI No.

PREPARED BY: ISSUE DATE:

QC SNAMPROGETTI COMPANY


Date Date Date Date

Location:

Project:

PAGE OF

ORIFICE FLANGE N.

INTERNAL GRINDING OF WELD ROOT

ORIF. FLANGE ORIENT. PRESSURE HOLES

SEAL WELD OF

THREADED JOINTS

NAME NAME NAME NAME

Client: Job. No : 315900

SAUDI ARAMCO Date :

Location: Unit :


Snamprogetti Project: :

SA KHURAIS CRUDE CONTRACT

Piping/Equipment Internal Cleaning Inspection Report (SATR-A-2008 Rev.2)

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION TEST SYSTEM No./Test Pack No. PLANT NO.

DRAWING NUMBER (P&ID/ISO) / REV. No. PIPE CLEANING DIAGRAM (If applicable) LOCATION WORK PERMIT REQD?

SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME

SAUDI ARAMCO TIP (SATIP) NUMBER SATIP Activity No. TEST IN ACCORDANCE WITH: a) Procedure No. b) Supporting SAIC No.

System Description:Service Fluid: MAOP: System Material Type:

Internal Cleanliness Report for On-Plot Piping & Equipment (See Remarks)

Internal Cleanliness Report for Pipelines (Note 2)

Drawing No: Location / Date

Section No: Test No:

From KM: To KM:

Scraper Type

RUN 1 RUN 2 RUN 3 REMARKSDATE TIME DATE TIME DATE TIME

Cleaning Start

Cleaning End

Cleaning Duration

OBSERVATIONS:

2. Scraper

RESULT (ACC/REJ)

Contractor / Third-Party Saudi Aramco

Name, Initials and Date:Work is Complete and Ready for Inspection:

Name, Initials and Date:T&I Witnessed QC Record Reviewed Work Verified

QC Inspector PID Representative

Name, Initials and Date:Performed Inspection Work / Rework May Proceed


QC Supervisor Proponent and Others

Name, Sign and Date: Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified

System No.

Method of internal cleaning (For piping systems and equipment)

Limits of internal cleaning(State Partial or Full and terminating ends)

Type Of Debris(sand, mill scale, electrodes, debris, etc.)

Valve Cavities & Other Low Point System Components

Pipeline Description : ____________________________________________ Pipe Internal Diameter(s): _________________

1. Indicate Amount and/or type of debris

REMARKS: Note 1: Items in italics above are for guidance in completion of forms prior to pressure testing. N ote 2: Valves should be installed in systems after pressure testing whenever possible during system reinstatement. Code fabricated test implements can easily replace valves during system hydrotests. Cavities & other low points in the line where debris can accumulate require special attention during cleaning. Typical flushing with air or water is inadequate in the removal of debris from valve cavities and low points. This accumulated debris (sand, scale, metal shavings, slag, etc) Construction Representative* PMT Representative

Name, Organization,Initials and Date:

Name, Sign and Date: Quality Record Approved:

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED



SAUDI ARAMCO Date :

Location: Unit :




Piping / Equipment Internal Cleaning Inspection SAIC-L-2017 1-Dec-06 MECH-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 ONLYSAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE

A

A1

A2

B Method 1: Progressive Internal inspection (DURING ASSEMBLY)

B1

B2

B3

B4

C Method 2: Internal Cleaning by Water Flushing

C1

C2

C3 Full bore valves (ball & gate valves) are in full open position.

C4

C5

System No.

ITEM No.

General Requirements (Note: Use SATR-A-2008 to document findings using this checklist)

Method of cleaning & flushing of piping spools & systems applicable for every individual system category was approved/agreed upon by PMT, Proponent and Inspection. (SAES-A-004, Para. 7.1.2 )

SAES-L-350,Para. 15.1

Visual verification of end limits covered by this inspection conformed with the QR (Quality Request for inspection)


Spools are visually inspected for internal cleanliness (no presence of loose particles/flakes or debris) prior to welding/bolting to the preceeding and/or succeeding spools. (Follow Notes Below)A) Visual inspection includes use of video inspection techniques, visual, scraping & positioning in vertical position. B) Fine dusts are acceptable, unless specified for critical systems

SAES-L-350,Para. 15.3.2

Ends of Piping spools or partially completed piping system passed visual inspection for internal cleanliness, were covered & sealed to prevent entry of debris (moisture, water or other foreign materials).Note: Each section of cleaned spools or system shall be recorded

SAES-L-350, Para 15.2.3

End covers were not and cannot be removed by unauthorized personnel prior to making the joint of succeeding sections of piping.A) QA/QC and/or Aramco Project Inspection shall be notified prior to removal of the end covers. B) End covers removed without authorization shall make the internal cleanliness null and void.

SAES-L-350, Para 15.2.3

Partial cleanliness inspection certificates for each section of a completed system are accounted for. Note: Where cleanliness cannot be fully verified, systems shall be cleaned by Method 2 or 3, whichever is applicable.)


Equipment sensitive to damage during water flushing are identified and isolated. (Ex: Flow meter, sight glass, soft-seated valves)

SAES-L-350,Appendix A

Equipment and in-line instruments that may interfere with the flow of water and debris are removed. (Ex: check valve, control valve, sight glasses,orifice plates, venturies, positive displacement and turbine meters and other in-line equipment., etc.)

SAES-A-004,Para. 7.1.4

SAES-L-350, Appendix A

Flushing medium used are any of the following:A) Plant/process waterB) Raw water (Fire water OK when process water is not available)Note: Sea water is not acceptable


For stainless steel lines, flushing medium chloride ion content is less than 50 mg/L. (NOTE: After flushing, the piping systems shall be completely drained, dried to a dew point below -1°C)


C6 For lines below 4" dia., minimum velocity of water fushing is 3 m/s.

C7

D Method 3: Pneumatic Flushing

D1

D2

E Method 4: Pressurized Air Shock Blowing (PASB)

E1

E2

E3

E4

F Method 5: Mechanical Scrapers

F1

F2

F3 Internal scrapers have full bore contact with the pipe diameter. Procedure detail

F4 Procedure detail

REMARKS:

Note 2: Limits of internal cleaning state whether cleaning was full or partial and details the system limits for cleaning

(specific line #) and/or equipment details/limits "as inspected"

Note 3: Type of Debris found states what was found during cleaning and any other unusual findings that could affect

system integrity "as inspected"

Note 4: Valve Cavity & other system low point component cleaning states exactly how low points remaining in line or the

equipment were cleaned. methods are adequate for removal of debris (sample selected by Company to witness shall

demonstrate this). See Explanation below.

Explanation: Valves should be installed in systems AFTER pressure testing when possible during system reinstatement.

THE ABOVE STATEMENT IS CLEARLY STATED AND INTENDED IN SAUDI ARAMCO STDS TO PREVENT VALVE SEAT DAMAGE.

Code fabricated test implements can easily replace valves during system hydrotests. Cavities & other low points in the

line where debris can accumulate require special attention during cleaning. Typical flushing with air or water is

inadequate in the removal of debris from valve cavities and low points. This accumulated debris (sand, scale, metal

shavings, slag, etc) creates serious corrosion and operational problems for COMPANY. Cleaning methods shall

demonstrate adequate cleaning for all piping system components and equipment. Where items such as valve cavities

exhibit an inadequate level of cleanliness, adequate cleaning & inspection shall be performed at earliest opportunity and

addressed no later than immediately after hydrotest. Avoid flushing lines through valves & install field hydrotested valves

"after" system testing where possible. Preservation checks of valves utilizing "AMBIENT" Lay-up methods is required.

REFERENCE DOCUMENTS:


For lines 4" dia. and above, high pressure jet (rotating hose or nozzle) at a minimum pressure of 60.8 mPa (8.8 psi) is used.


Medium used for pneumatic flushing is dry air (dew point -1°C or less) or steam with a minimum exit velocity of 15 m/s.


Flushing is repeated until cleanliness is verified by observing the absence of any solids impact on a polished metal target at the exit.


PASB method is used for the following conditions: a. For initial cleaning of instrument air, plant air b. As an alternative method for initial cleaning of small bore pipe (less than 2 inch). c. Presence of trapped liquid in the piping, or if verification of cleanliness using video inspection is not possible.


The air shocking pressure shall never exceed the working pressure of the system and shall never be more than 810 kPa (115 psi).


Safety precautions are considered in consultation with Area Loss Prevention Division.


PASB is repeated until cleanliness is verified by observing the absence of any solids impact on a polished metal target at the exit.


Mechanical scrapers are used on piping system that will not cause damage to the pipe interior surface (ie: piping with internal coating).


Degree of cleanliness conforms with the approved internal cleaning procedure.


Additional checkpoints or Acceptance Criteria shall be added upon approval of Piping Internal Cleaning Procedure by scraping.

ATTACHMENT:

NOTES FOR SATR-A-2008 USE:

Note 1: Method of internal cleaning states in detail the cleaning methods used (reference Company approved procedure)









1. SAES-A-004, General Requirements for Pressure Testing, (30 march, 2005)2. SAES-L-350, Construction of Plant Piping, (30 September, 2003)3. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003)

Construction Representative* PMT Representative



SAUDI ARAMCO Date :

Location: Unit :




Inspection of Filling & Pressurization (Hydrotest) SAIC-A-2013 1-Dec-06 MECH.

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






A General Requirements

A1

A2

A3

A4

A5

A6

A7

System No.

ITEM No.

Pressure Test Procedure is approved and all safety precautions per GI-0002.102 & SAES-A-007 (Chemical Handling) have been taken.

SAES-A-004, Section 5.1

All in-line valves (if not test isolation) are open*. Note: A fully open valve can leak at stem packing. Items that interfere with filling & Sensitive equipment have been removed from the piping system. System test limits are checked during Inspection walk down

SAES-A-004 Para 8.1.3

Inject oxygen scavenger, biocide and other treatment chemicals continuously at a rate that will provide the specified concentration while filling the system for the hydrostatic test. See Attachment 1 Ensure safe filling of systems with properly proportioned chemical treatments. See Attachment 1 for these details.

SAES-A-007 Section 8

Filling & pressurization is done upstream of check valves in system. Test fluid enters (shall be drained) at the lowest point in the system. All vents are open during filling. Minimize Trapped air. See Attachment 1 (Hydrotest Filling & Venting Practices) Quality Manager & Inspection Action Required for Efficiency


Remove air during filling by the following measures: A) Design/Plan Tests. Provide high point vents. B) Mechanically (Use scrapers as needed to remove air). C) Follow Attachment 1 regarding Efficiency Note: Venting may be accomplished by vent valves or blind flanges with properly attached test implements (welded couplings, etc) that are located at the highest point in the flange to minimize trapped air.

GI-002.102, Para. 5.15

After venting, valves used for venting are placed in the partially open position and plugged or blinded as applicable.


Procedure requirements are followed step by step: A) Test Medium is applied as per approved test package B) Test sequence is controlled. Maximum test pressure is per approved test package SIS sheet & Pressure Test Report Form. C) Pressure rise is staged (Adequate* hold time between stages) D) Inspection & Test Crew follow safety responsibilities during testE) Safeguards (clearance, barricade, signs, permits) are in effect *10-minute equalization time is an approximate value used in the GI.

GI-002.102, Attachment 1,

Section 2

A8

A9

ATTACHMENTS:

Attachment 1 - SAES-A-007 Hydrostatic Test Water Preparation, & Hydrotest Filling & Venting Practices (Efficiency)

Attachment 2 - Efficient Practice For Acceptance of Pressure Tests


1. SA General Instruction Manual GI-002.102, Pressure Testing Safely, (July 22, 2001)

2. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005)

3. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (5 October, 2005)

4. 32-SAMSS-004, Manufacture of Pressure Vessels, (30 March, 2005)









Preliminary check for leaks at 50% of the strength test pressure was performed. Test crews were efficient in filling practices. See Attachment 1 regarding Testing Efficiency

GI-002.102, Para. 5.16

Temperature of the water during hydrostatic testing was maintained well above 60 degrees F (16 C) due to Brittle Fracture consideration A 17°C Value is listed in 32-SAMSS-004 (tanks). This equals 62.6 F. Note:This should never be a problem in Saudi. However, air temps can drop to below 10 C & water temperatures will drop as well. Water temps for Pipeline & Plant Piping testing should also follow this minimum reqmt. Document the "actual" test temps when low. Note: On the other end, solar heating can create problems when testing small diameter piping sections, with difficulty in achieving successful test results. However, when efficient filling practices are utilized & tests are well coordinated, this is NEVER a problem. See Attachment 2.

32-SAMSS-004 Para 16.3.10

REMARKS:




SAUDI ARAMCO Date :

Location: Unit :




Visual Inspection at Test Pressure SAIC-A-2015 1-Dec-06 PIPE-EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.






A General Requirements ... Use SATR-A-2001 with this checklist

A1

A2

A3

A4

A5

A6

A7

REMARKS:

Attachment 3 - Walkdown Inspection Techniques ----------- Attachment 4 - SAES-L-150 Pressure Testing Application & Insp

System No.

ITEM No.

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 closed and the test pump disconnected. See Attachments 1 & 2.

SAES-A-004, Para. 8.1.2

All joints including welded shall be left exposed for visual leak detection during the strength test. External coating & priming of such joints is not allowed unless approved by the Manager of Inspection Department and the proponent Organization representative. The pipe itself can be externally primed and coated to a final coat. See Attachment 3 (Walkdown Inspection Technique).

SAES-L-150, Para. 7.3

The test pressure shall be maintained for a sufficient time, but shall not be less than 30* minutes, to determine that there are no leaks. *Large systems (Plant Piping) can take longer to complete.


Exceptions to Item A3 above, Plant Piping Pressure Testing & Visual Inspection Requirements. See Attachment 4. Visual Inspection & Testing meets SAES-L-150 reqmts.

SAES-L-150, Section 7

Plant Piping

Exceptions to Item A3 above, Pipeline Pressure Testing & Visual Inspection Requirements. See Attachment 4. Visual Inspection & Testing meets SAES-L-150 reqmts.

SAES-L-150, Section 8

Pipelines

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. Valve Testing details are included in separate Procedure

SAES- L-108, Para. 4.7.6

Test Records for each test are entered on a Pressure Test Report Form 2642-ENG. Test duration & Acceptance is shown in Comment section of report. (Tape has test pressure & test start/finish time) Remove tape from gage & press into Test Report. Attachment 2.

SAES-A-004, Para. 8.3

ATTACHMENTS: Attachment 1 - Pressure Testing Details --------- Attachment 2 - Efficient Practice For Acceptance of Pressure Tests

2. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003)

3. SAES-L-108, Selection of Valves, (30 March, 2005)









REFERENCE DOCUMENTS: 1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005)




SAUDI ARAMCO Date :

Location: Unit :




Pressure/Leak Test Report (SATR-A-2001 Rev.2)


DRAWING NUMBER (P&ID/ISO) / REV. No. PRESSURE TEST DIAGRAM NATURE OF TEST WORK PERMIT REQD?

SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME LOCATION OF TEST (PLANT NAME & NO.)

SAUDI ARAMCO TIP (SATIP) NUMBER SATIP Activity No. TEST IN ACCORDANCE WITH: a) Procedure No. b) Supporting SAIC No.

System Description: Test Details (Type):

Test/Service Fluid: MAOP: Sys Mat'l Type: Limiting Factor:

Flushing Cleaning Method Used: Accepted: Rejected:

Lay-Up Method: None: Ambient: Wet: Dry: Other :

Test InstrumentsPressure Gages/Recorder Temp Gage/Recorder Relief Valve

PG- PG- PG- PG- PR- TG- TR- RV #

Serial No/Tag No.

Make

Range

Certificate No.

Date Calibrated

Set Pressure

Actual Pass Fail Remarks

1

2 SystemTemperature at test:

3

4

5

6

7

REPAIRS DURING TEST:

Rejected

REMARKS:


Test is ready for inspection: T&I Witnessed QC Record Reviewed Work Verified


Name, Initials and Date:Witnessed Test Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified

QC Supervisor Proponent and Others (Optional)

System No.

Re-Calibration Due Date

ITEM No.

Description of Test Parameters(Complete Applicable Data Entry Prior to Test)

Test Medium Type/Quality (Indicate method of treatment if req'd in Remarks, i.e., Fluid type, ph, SRB count, O2 Scavenger, etc).

Test Pressure: Strength Test: ___________Tightness Test: ___________

Service Test/Others:________Valve Body: ______________Valve Seat: ______________

Preliminary Test Conducted at __________Psig

Area of interest (Indicate flange joints, weld joints, threaded, socket, body)

Method of leak detection (direct visual/remote)

Test Duration : a. 30 minutes min for Plant Piping b. 2 hrs. Pipeline strength test/ ______ Tightness Test c. Others_____________

TEST RESULTS:

Test Accepted. No leak or loss in pressure observed. AFFIX ANY TEST TAPE TO THIS REPORT (TEST EVIDENCE)

State reasons in Remarks Section.

Construction Representative /Piping Engineering PMT Representative

Name, Title, Department,Company, Initials and Date:

Name, Initials and Date:

Name, Initials and Date:

Name, Sign and Date: Quality Record Approved: T&I Witnessed QC Record Reviewed Work VerifiedName,

Organization,Initials and Date:


SAUDI ARAMCO Date :

Location: Unit :




Verify Test Equipment (Safety Assessment) SAIC-A-2009 1-Dec-06 MECH-







Note TEST EQUIPMENT SAFETY ASSESSMENT (Notes 1-7) ... Perform along with SAIC-A-2011.

1

2

3

4

5

6

7

A Test Manifold & Appurtanances (Piping, Fittings, Hoses) - Verify Test Package Content before Testing

System No.

ITEM No.

On New & Existing Projects, Test Equipment shall be thoroughly inspected & certified for safety (new & existing test equipment). Responsible persons shall be Project QA/QC Mgr and designated Hydrotest Engineer and Mechanical Inspector(s).

Regular inspection/maintenance of appropriate test equipment is mandatory to assure Safety on SA Projects. Use of existing equipment is permitted if equipment does not exhibit signs of deterioration & is regularly inspected (Per Note 7) and meets GI-2.102 Safety Requirements. Recommended is use of corrosion inhibitor when equipment is not in use for long periods.

Check component corrosion & wear (especially small fittings, nipples, etc) on existing equipment, especially test pumps. A thorough visual exam includes accessible internal components (use mirror & sunlight technique), a UT exam or hammer test (never hammer pressurized piping). Perform this exam in presence of COMPANY Inspection for new projects just prior to testing existing manifolds. Fittings and components found with heavy corrosion or thinning (verified wall loss) shall be replaced. Heavily Corroded fittings give a dull sound when hammer tested (new steel = ringing sound). Perform UT on suspect fittings or replace ASAP.

Existing Manifolds proposed for use on projects without detailed code construction documents (Engineering calcs & Inspection) must be certified for fitness and safety. Existing test reports alone are not acceptable support documents. Code construction detail, calculations (SIS sheet), appropriate Inspection and NDE are necessary for Safety. Unknown piping schedules can be determined by using a UT Thickness meter. Ratings for most fittings are stamped/visible. Weld quality is verified by VT or RT. Test manifolds frequently used, older than two years and stored in ambient conditions are highly susceptible to accelerated internal corrosion and thinning of components due to corrosive nature of test waters used in many locations. Detail Manifold Arrangement Dwgs.

Fabricated test components (blinds, spools, welded couplings, etc) are of proper code construction, receive inspection and are properly identification/marked for their pressure rating, inspection acceptance/fitness (Insp Ok, initial, date). Never allow uninspected non-code test component use. Components found unfit for testing (non-code, under thickness or schedule & without calculations, deteriorated, damaged, corroded) are reported and removed ASAP from Company Projects.

Manifold design shall include limiting factor for all components (isolation valves, piping, fittings, tubing, etc). that are calculated (by design) to provide a PRESSURE RATING of 20% above the maximum expected system for test. Isolation valves shall be one Class higher than systems tested. Example: Project's greatest System Class = Class 900, CS (Normal), pressure rating 2,220 psi (test pressure = 3,350 psi). A manifold is needed to meet COMPANY safety requirements. Step 1: Maximum test pressure for Class 900 systems = 2,220 x 1.5 = 3,330, round up to nearest increment of 25 = 3,350 psi. Step 2: Manifold minimum design pressure (manifold test pressure) SHALL = 3,350 x 1.2 = 4,020 psi. Step 3: Manifold isolation valve must be Class 1500 minimum (one class above Class 900) See ASME B16.34 Tables & Para 7.2 = a 110% pressurization rule for valve seat closure tests. Step 5: Components (piping, fitting, tubing, etc) are rated for 4,020 psi minimum and have engineering calcs to support their use. Manifolds without construction details (arrangement drawings) are not accepted until CERTIFIED & RATED for Safety.

Perform safety checks for Notes 1-6 at least yearly* & before the start-up of pressure testing on projects. *Observation: The Diving Industry requires appropriate test equipment maintenance inspections on an annual basis. Scuba Tanks are pressurized frequently to 3,200 psi, often on a daily basis. Annual inspections use remote visual means (fiberscope). Corroded Tanks are replaced before they fail. Pressure Testing equipment sees similar and even greater pressures and service use. Safety of Test Crews, Inspectors & personnel on Projects deserve similar consideration. Keep Test equipment in good condition (Coated as needed, clean, legibly rated for pressure, legibly marked "as inspected, and regularly inspected).

A1

A2

B Verification of Actual Test Equipment Set-up (Manifold Arrangement)

B1

B2

B3

B4

B5

C Test Relief Valve(s)

C1

C2

C3

D Pressure Gages and Recorders

D1

D2

Manifold Arrangement Drawing(s) attests to equipment safety: A) Fabrication is per code construction with component details listed such (Class, size, schedule piping, type isolation valve, etc). B) Maximum Safe Test Pressure Rating based on limiting factor. C) Each test manifold is identified with a unique number (certificate) D) Shows actual arrangement including hose configuration used Note 1: Manifold permanent marking (unique ID #, pressure rating) is legible, traceable & certified for safety (Support documenation).

G.I.-2.102,Para. 5.5

Manifold Design Pressure Rating (Compare SIS for manifold & the system to be tested) exceeds system test pressure by 20%.

G.I.-2.102,Para. 5.5, Safety Note 6

Test Set-up* matches actual Test Manifold Arrangement. Note 1: *Pressure Test Diagram with an appropriate Legend for symbols, Test Manifold Arrangement (& pressure hoses/piping) show all high points (vents), low points (drains), gage locations & provide documentation that attests to the actual test as performed. In event of testing accident, Loss Prevention Dept must be able to use diagrams & sketches to recreate actual test set-up/conditions.

G.I.-2.102,Para. 5.2 b, SAEP-1160,

Section 8

Blow down valve is adequately rated at higher class than system under test, and is installed to depressurize the system safely and is easily accessible to operator. (Safety Note 6, Isolation valve)

G.I.-2.102,Para. 5.5

Temporary Test Piping, spools, fittings to equipment and hose connections have adequate* pressure ratings, as marked, stamped or documented in test pkg. (*Match/exceed test pressure)

G.I.-2.102,Section 4

Hoses are adequately rated, in good condition, safely arranged (tripping hazards) and protected from Heavy equipment traffic.

G.I.-2.102,Section 4

Paddles or spectacle blinds & other fabricated test items for isolation are at least the same code class rating of systems under test or have code calcs to support them. Safety Note 5

SAES-A-004 Para. 7.3

Relief valve is located in the system under test and near the test pump with Isolation valves on the inlet and outlet of the relief valve sealed open during the test. (SAEP-1160, Bullet Item # 3)

G.I.-2.102,Para. 5.5

Relief valve(s) of adequate capacity (*SIS Sheet & Calcs available) are set to relieve at 5%* above the hydrotest pressure. *Note: Test pressures less than 85% of SMYS can have relief valves set at 10% above test pressure. Verify SIS sheets/calcs.

SAES-A-004 Para 5.5

Tested relief valve(s) with a tag stamped with the word "TEST", the set pressure, and date is checked. Stamp date validity is a period of one week for project pressure tests. Stickers are legible & valid. A roster is kept for Pressure Relief Valves (M&TE) on projects.

SAES-A-004 Para 5.5

A minimum of two pressure gages are required for test systems, with accuracy within 5% of one another. Note 1: When large systems are tested, Inspection personnel will determine the need for additional gages. Note 2: Elevation changes (hydrostatic head considerations) & hot weather create pressure testing problems with frequent popping of relief valves. For this reason, gage accuracy within 2% is best. Note 3: Careful handling of delicate instruments as test gages is practiced by test crews. No gage damage or mishandling is found.


Pressure gages and pressure recorders are calibrated within (1) month prior to test. Stickers applied indicate latest calibration date.


D3

D4

E Temperature Gages and Recorders (When Required, ie: 24-hr Recorded Tests)

E1

E2


1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005)

2. GI-2.102, Saudi Aramco General Instruction-Pressure Testing Safely, (22 July, 2001)

3. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003)

4. Pro Forma Contract Schedule Q (Nov 2003)

5. SAEP-1160 (First Edition June 7, 2006)









Test gauge is located at bottom of any equipment/system under test to enable reading test pressures inclusive of hydrostatic head. Note: Locate test manifold (with gage) at low points in systems under test. One foot of water (30 cm) @ ambient temperature = pressure increase of .433 psi. (1-meter = 1.42, 10-meter = 14 psi).

G.I.-2.102,Sec.4 & SAES-A-004,

Para 5.3

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


Bubble Leak Test (associated with Pneumatic strength/service test) surface metal temperatures shall be recorded and compatible with test methods (including test solution used to detect leaks). Note: ASME V, Art 10, Man. App. 1, Table 1-1021 requires surface metal temp measurements during testing (detailed in procedure). Record maximum (direct sun) & minimum test temperatures.


Thermocouples are installed to obtain accurate pipe metal temperature measurements and to determine the acceptance of the pressure test where pressure variations due to test water temperature changes occur, such as in cross-country pipelines.


REMARKS:




SAUDI ARAMCO Date :

Location: Unit :




Depressurization & Disposal of Hydrotest Water SAIC-A-2017 1-Dec-06 MECH.








A1

A2

B Specific Disposal Requirements

B1

B2

B3

B4

B5

B6

B7

System No.

ITEM No.

Depressurization is done slowly and safely after completion of test or on discovery of leaks. Bleed off the system slowly to an approved safe discharge area and monitor discharge.

GI-002.102, Section 5.17

Inspection ensures written procedures approved prior to testing are followed upon disposal of any test medium containing chemical additives for control of corrosion and bacteria. Disposal methods follow SAEP-327, Section 3 requirements.

GI-002.102, Section 5.20

New pipelines, and pipelines in gas service do not require oil/water separation prior to wastewater discharge/disposal

SAEP-327, Section 3

Do not discharge wastewater to local wadi environments. Discharge separated wastewater to non-sabkhah areas into approved pits or to lined evaporation ponds constructed.

SAEP-327, Section 3

As far as possible locate the disposal site within the existing pipeline corridor while ensuring adequate pipeline access and without causing damage to the existing roadways, pipelines, private entities or other structures

SAEP-327, Section 3

Do not dispose wastewater within or adjacent to wetland or sensitive environments, including specified conservation areas

SAEP-327, Section 3

Disposal to Sabkhah Discharge separated wastewater directly to the sabkhah for evaporation provided that the wastewater remains on land, and does not flow directly to the marine environment. An oil/water Separator Pond is required before wastewater is discharged to sabkhah to ensure retention of residual hydrocarbon for subsequent collection and proper handling. Separator pond site is downwind to minimize exposure risk to nearby facilities personnel.

SAEP-327, Section 3

Disposal to an Evaporation PondOil/water separator ponds are required upstream of evaporation ponds to collect residual hydrocarbon and improve evaporation in the evaporation ponds.

SAEP-327, Section 3

Disposal to Industrial Wastewater Treatment PlantDischarge wastewater directly to the local industrial wastewater treatment plant if disposal does not affect the normal operations of the plant. Obtain concurrence from the operators of the treatment plant prior to selection of this disposal option.

SAEP-327, Section 3

B8

B9

B10

B11

B12

B13

B14

B15

B16


1. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (5 October 2005)

2. SAEP-327, Disposal of Wastewater from Cleaning, Flushing, and Dewatering Pipelines and Vessels (31 May, 2003)

3. SA General Instruction Manual GI-002.102 (July 22, 2001) Pressure Testing Safely









Disposal to Injection WellDispose wastewater into injection wells if it does not affect the well operation. Obtain concurrence from the operators of the well prior to selection of this disposal option. Injection well operators will provide water quality criteria for any wastewater that will be introduced to their system for disposal

SAEP-327, Section 3

Disposal OffshoreDispose wastewater offshore to the Arabian Gulf or Red Sea per SAEP-327 Table 1 (See Excel Sh # 2 Att'd). Adequate dispersal of wastewater in marine environment by diffuser or similar method or transfer wastewater onshore for treatment/disposal.

SAEP-327, Section 3

Biocides other than Troskil-1 (Polyhexamethylene biguanide hydrochloride or PHMB) require evaluation & approval by EPD/EED prior to disposal to the Arabian Gulf or the Red Sea. Water Disposal Approval Form has been submitted

SAEP-327, Section 3

Dispose wastewater with Rhodamine B and TROS (fluorescent) dyes into deep water, shallow water and embayment systems per SAEP-327 Table 1 (See Excel Sh # 2 Attached). For other dyes provide toxicity data, submit Water Disposal Approval Form. Notify Frontier Force of any discharges of dyes to sea to prevent alarm.

SAEP-327, Section 3

Use a spray nozzle to allow maximum oxygenation of discharge of waters containing oxygen scavenger added

SAEP-327, Section 3

Submit Water Disposal Approval Form and obtain approval from EPD/EED before discharge of any wastewater to embayments and/or conservation areas in the Arabian Gulf

SAEP-327, Section 3

Discharge of contaminated wastewaters follows SAES-A-103. A) Discharge locations are where water columns are deepest. B) Discharge there is as close to the water surface as practicable. C) If only oxygen scavenger is used, discharge is into the air and discharge rate is less than five cubic meters per minute D) Alternatively, SAES-A-104 allows injection of wastewater into any petroleum reservoir producing hydrocarbons.

SAEP-327, Section 3

Submit Water Disposal Approval Form and obtain approval from EPD/EED before disposal of wastewater to the Red Sea

SAEP-327, Section 3

For pipelines, dewatering is performed by scraping. If sea water was used for testing a pipeline, remove salt deposits by scraping with slugs of water containing less than 4500 mg/L total dissolved solids until the water soluble sulfates and chlorides on the steel surface at the drain or outlet end are reduced to <80 mg/m².

SAES-A-007 Para 5.2.3.1

REMARKS:




SAUDI ARAMCO Date :

Location: Unit :




System Lay Verification Report and Certificate (SATR-A-2009 Rev.2)

Note: This Cert is used for Lay-up Checklists SAIC-A-2018 (Plant Piping & Equipment) & SAIC-L-2124 (Pipelines)

Certificate No. Date:

Equipment: Service Fluid:

System Lay-up Duration: Start - End Date:

Hydro Test Medium: Type of Lay-up:

METHOD OF LAY-UP Actual Pass Fail Remarks

Wet Lay-Up

Dry Lay-Up

Dry the system to a dew point of -1°C

Shut in system (positive pressure) not less than 12 hours

Measure Dew Point Temp -1°C or less after Shut-In Period

Shut in system, maintain & monitor during lay-up period.

Inert Gas Lay-Up

Ambient Lay-Up

Cover pipe to prevent ingress of dirt and moisture

Vapor-Phase Corrosion Inhibitor (VCI)

System shut-in to prevent ingress of moisture and debris









System No.

Minimum residual oxygen scavenger concetration in water shall be 20 ppm & maximum O2 concentration of 10 ppb

Maintain the system under a positive pressure between 30 to 50 psig using nitrogen, sweet hydrocarbon gas or hydraulic pressure of the treated water

Use gages to monitor the positive pressure in the system during lay-up with a scale range not exceeding three times the target pressure. (Gages must withstand MAOP)

Use gages to monitor the positive pressure in the system during lay-up with a scale range not exceeding three times the target pressure. (Gages must withstand MAOP)

Test water drained from the system until no visible water or moisture is present.

If sea water was used for testing, remove salt deposits until sulfates and chlorides on the steel surface reduced to less than 80 mg/msquare.

Displace the hydrostatic test water with nitrogen or sweet gas until no water drains out of the system.

Shut in the system at 2-10% of operating pressure but not exceeding 50 psig with nitrogen or hydrocarbon gas.

Test water drained completely until no visible water or moisture is present.

Valves (400 SS or 13CR trim, etc) tested in-line having cavities were removed, dried & relubricated per procedure

Test water drained completely until no visible water or moisture is present.

Volume of System: _______Amount of VCI Applied: _______



Name, Sign and Date: Quality Record Approved:

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED



SAUDI ARAMCO Date :

Location: Unit :




Review Procedure - Lay-up of Piping Systems or Vessels SAIC-A-2007 1-Dec-06 0








A1

A2

A3

B CARBON STEEL & LOW ALLOY (P-No. 3/4/5) PRESSURE PIPING SYSTEM LAY-UP (See Section C for Specific Applications)

B1

B2

B3

System No.

ITEM No.

Lay-Up Procedure or Method Statement shall be project specific and identified in Project Quality Plan. (SPECIAL CONSTR. PROCESS). Note Significant changes to SAES-A-007 (Oct 2005 Revision)

Sch Q, Para. 3.1

As SAES-A-007 is intended to be a procedure guide, the Contractor shall cut and paste as much of the document as applicable into any procedures to be submmited to Saudi Aramco for review/approval.

SAES-A-007, Section 1

(Scope)

Procedure covers SAES-A-007 General Reqmts regarding: A) Water Quality B) Planning & System Design for Lay Up See Attachment 1


Procedure details Treatment of Hydrostatic Test Water: When the CS equipment contact time with hydrotest water may exceed 14 days (14-day rule), approved oxygen scavenger (App. 1) shall be added to the hydrostatic test water. Treat water before it enters the system. Use batching scrapers and/or a slug of nitrogen to separate the air in the system from coming in contact with treated water, then fill systems with water injecting sufficient oxygen scavenger to maintain its residual concentration at greater than 20 ppm & an oxygen concentration of less than 10 ppb.

SAES-A-007,Para. 5.1

Procedure meets/addresses/details the following requirements: A) Equipment must be laid-up after hydrotesting unless it can be ensured that it will be returned to service within 30 days from the first introduction of hydrotest water to the system. B) One of the lay-up methods in Item B3 shall then be selected. C) Section C of this checklist (Specific system & equipment reqmts) D) Lay-up procedures for pipelines under the responsibility ofPipelines Dept shall be approved prior to hydrotest by the GeneralSupervisor, Pipelines Technical Services Division (PTSD), & by theMgr of the concerned area. Approval of lay-up procedure for otherequipment shall be the responsibility of SA Eng Suptd. or designate.


Procedure identifies different lay-up methods selected: A) Wet Lay-up (Attachment 2) B) Dry Lay-up (Attachment 3) C) Inert Gas Lay-up (Attachment 4) D) Ambient Lay-up (Attachment 4) E) Other Approved Lay-up Methods (Attachment 4)


B4

B5

C SPECIFIC & SPECIAL LAY-UP REQUIREMENTS (Specific Applications)

C1

C2

C3

C4

C5

D STAINLESS STEEL PRESSURE PIPING SYSTEM & EQUIPMENT (P-No. 6 & above) LAY-UP (INCLUDING NEW VALVE REQMTS)

D1

D2

D3

Procedure states step by step for implementation of Lay-up method: A) Verify the appropriate steps cover specific lay-up procedure in attachments 2, 3, & 4 and refer to SAIC-A-2018 (Application). B) SAIC-A-2018 & SATR-A-2009 may be used as a supplementary Lay-up Procedure.

SAES-A-007,Sec. 5.2.1

At end of lay-up, commission & start up heat exchangers shall be within 14 days, & other equipment within 60 days. This statement is included in Procedure for Carbon Steel Equip.


Tank requirements are listed in applicable procedures: Carbon steel open-roof, floating-roof, or API atmospheric coneroof tanks not designed for service above atmospheric pressure, do not require treatment of of hydrostatic water. Immediately after completion of the hydrostatic test, drain and remove all traces of visible water. Cleaning shall consider any coating operations.

SAES-A-007, Para 7.1

Utility System requirements are listed in applicable procedures:A) Utility and potable water systems shall be tested in accordance with SAES-S-060 or SAES-S-070, as appropriate.B) Potable water systems shall be tested with fresh potable water only following the requirements of SAES-S-070, Para 18.2. Oxygenscavengers and biocides shall not be used in potable systems.C) For potable water systems, use Dry lay-up per Para. 5.2.3, Inert gas lay-up using nitrogen per Para. 5.2.4, or Ambient lay-up per Para. 5.2.5. See Attachments 3 & 4. D) For Dry-up (moisture removal), sweet gas shall not be used. Methanol or other dehydrating chemicals shall not be used. Procedure details dry-up methods used & means of verification

SAES-A-007, Para 7.2

Dry Gas & Refined Hydrocarbon Product Pipelines & Piping. See Attachment 5.


Sour Gas & Sour Oil Pipelines. See Attachment 5. SAES-A-007, Section 7.4

PLANT SYSTEMS (PIPING & EQUIPMENT) SHALL BE LAYED UP PER ATTACHMENT 6. Inspectors are familiar with these reqmts.


Type 300-series stainless steel systems* shall be tested only with water having maximum allowable chloride concentration of 50 ppm. Quality of water shall be per Attachment 1. Para. 4.2 in entirety. CS system with 300 Series SS trim valve is not a SS "system". WATER QUALITY IS TESTED & CERTIFIED (SATR-A-2014)


Type-400-series stainless steels are highly prone to atmospheric corrosion. This includes valves with trim designated 13Cr*. *Note: Trims # 1, 4, 6, 7, 8, and 8A are affected by new rule. Corrosion Controls shall be implemented in procedures as follows: A) Type 400-series stainless steel trimmed valves shall be removed from pipelines before hydrotest. (In-line spools are used for testing) B) Option B: If it impossible to remove such valves from the line, then written hydrotest procedures must be prepared and approved ahead of time allowing the valves to remain in place. See Attachment 7 (Special Notes for 13Cr Trim Valves) Quality Managers & Inspectors are aware of the new reqmt

SAES-A-007, Para. 6.2 & SAES-L-105

Valve Trim Table

When equipment containing any Type-400 series stainless steels is left in place (Option B above), it shall be hydrotested per reqmts of Paragraph 6.3, 6.4, and 6.5 of SAES-A-007. See Attachment 7.


D4

NOTES: 1. Utilize SAIC-A-2018 and SATR-A-2014 in conjunction with this checklist.

2. Quality Managers shall ensure Procedures address the new revisions of SAES-A-007 & Valve Lay-up Considerations.

ATTACHMENTS:

Attachment 1 - SAES-A-007 (Oct 2005 Rev) GENERAL SYSTEM REQMTS

Attachment 2 - LAY-UP FOR CARBON STEEL SYSTEMS (WET METHOD)

Attachment 3 - LAY-UP FOR CARBON STEEL SYSTEMS (DRY METHOD)

Attachment 4 - LAY-UP FOR CARBON STEEL SYSTEMS (INERT GAS, AMBIENT & OTHER METHODS)

Attachment 5 - SPECIAL LAY UP PROCEDURES (Dry Gas & Refined Hydrocarbon Product Pipelines & Piping, Sour Gas & Sour Oil Pipelines)

Attachment 6 - SPECIAL LAY UP PROCEDURES (Plant Applications, Piping Systems & Equipment)

Attachment 7 - LAY UP PROCEDURE (STAINLESS STEEL SYSTEMS & EQUIPMENT)

Attachment 8 - SAES-A-007 Appendix 1, Approved Oxygen Scavengers


1. SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Procedures, (5 October 2005)









Hydrotest procedure shall carefully detail measures to prevent corrosion including lay-up of the equipment. See Attachment 7. Do not use ambient lay-up for equipment of 400-series SS.


REMARKS:




SAUDI ARAMCO Date :

Location: Unit :




Review Procedure - Post Test Reinstatement & Checklist SAIC-A-2006 1-Dec-06 Piping-







A General Requirements (Complete SATR-A-2007, listed as Attachment 5 & use SATR-A-2011 & SATR-A-6133)

A1

A2

A3

A4

Note info only

A5 Seal welding of threaded connections and NDT associated info only

A6 info only

A7 info only

A8 Installation of valves not tested in the line (field test and cert req'd) info only

A9 Instrument impulse line testing and completion (tested with sytem) info only

System No.

ITEM No.

Post Test Reinstatement Procedure & Checklist is required to be developed in accordance with & as part of pressure testing. This is a pressure testing procedure & test package component to be developed during package creation as based on workscope & specific "system" requirements. Comment: A standard post-test checklist does not provide a procedure for reinstatement. A detailed procedure to give clear field direction along with a checklist for this activity shall be submitted before the start of work.

SAEP-1160, Section 8

Inspection strategies & plans shall be prepared and agreed on prior to commencing of testing. This is in common with Pipelines. Pipelines simply follow their reinstatement procedure.


Specifically, Procedure shall detail PLAN or STRATEGY to reach "SYSTEM" COMPLETION (Quality Certification) as efficiently as possible while accomplishing critical goals of: A) Effective Water Removal, Disposal & Lay-Up (Post Test) No test fluid shall remain in low spots. Specifically, valve cavities. B) Test Vents and Drains (plugged, seal welded & PT'd) C) Removal & reconnection of components All temporary items installed for testing (e.g., manifolds, valves,blinds, spacers, supports) shall be removed. Valves Installed. Items that were removed from testing shall be reinstalled. Items, such as instrument air tubing, check valve discs reconnected (witnessed). Valve line-up & gasket installations meet specifications.

SAES-L-350, Para. 17.2 &


Effective Corrosion Control & Preservation Measures Inspection Coverage and Responsibilities (Package Clearance) Clearly detailed provisions for Retesting after reinstatement Evaluations by Inspection. Construction related provisions.


Note: The Pre-Test Checklist & Attachments 1-4 were left in this checklist. Many apply to post-test requirements and shall help Contractor develop this procedure & checklist. Further assistance can be provided upon request.

Welding of attachment welds for non-pressure containing parts such as wear pads.

Completion of open-ended Piping such as drains, vents and piping downstream of pressure relieving devices that discharge directly to the atmosphere (excluded from in-situ pressure testing).

A10 Coating & insulation, steam tracing & final inspection (Clearances) info only

A11 info only

C SAIC-A-2010 Checklist (Reinstatement Procedure & Checklist item required (when bold.

SPEC CHECK SHALL BE UTILIZED BY SAUDI ARAMCO INSPECTORS FOR FIELD WALK-DOWNS (See E-Library, Folder 25)

C1

C2

C3

C4

C5

C6

C7

C8 N/A

C9

C10

C11 Valve Line-up

C12

C13 Drains are provided immediately above check valves (vertical lines). water removal

C14

C15 Spare taps of orifice flanges are plugged and seal welded.

C16 Repairs

C17 Reconnect

C18 Preservation

C19 Inspection

C20 M&TE

C21 P&ID Line-up

C22

Support Installations & Reinspection of Systems for Plant Piping Alignment, clearances, fabrication tolerances and workmanship.

All joints (flange, threaded, welded or mechanical seals) are left exposed for visual leak detection during the strength test. A) External coating & priming of joints is allowed only if approved by Insp Dept Mgr & proponent Organization Representative. B) The pipe itself can be externally primed & coated to a final coat.

SAES-L-150,Para. 7.3 System clearance

(Controls)

Final Coating & Insulation

Protection Controls

Plan/Strategy

All permanent flange joints were inspected, gasket mat'l verified & properly torqued. (Review Flange joint report, SAIC-L-2014)


Final & Perm Gasket Install

Drains shall be provided at all low points of the piping system. Note: Exceptions are submarine & buried* pipelines (*pump-outs)


Water removal Lay-up

Vents and drain valves, both temporary and permanent, conforms with the piping class or rating. ( Refer SAES-L-108)


Plug, cap seal welding, PT

Supports are installed. Additional temporary support may be installed as required.


Tolerances, specs

Expansion joints and spring hangers or spring supports are provided with temporary restraints.


Final alignment, specs

Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity, uneven weld profiles, and undercut) shall be removed by grinding and inspected by magnetic particle or liquid penetrant method.

SAES-W-011,Para. 11.6

rework provisions, Controls, retesting

Temporary welded attachments to the pipe were ground off and inspected by magnetic particle or liquid penetrant method

SAES-W-011,Para. 11.7

All threaded joints and faying surfaces shall be seal welded by a continuous fillet weld (required weep holes shall be left unwelded).

SAES-W-011,Para. 11.15.1

pack heavy grease

Isolation valves are verified to have been body and seat tested prior to installation through verification of field test certificates.

SAES-L-108,Section 4.7

Valve Installation

All in line valves that are not used as test isolation valves are in open position.


During water filling, Permanent vent and drain valves are in open position and plugged, after water filling and air venting.

SAES-A-004,Para 8.1.1


Disc of check valve is removed, unless check valve has by-pass. Method for storage (plastic bag & tie) allows visual verification.


WITNESS POINT


All threaded joints up to the first block valve of hydrocarbon pipeline are seal welded. Thread engagement has been verified & accepted.


Process instruments and equipment that may be damaged by the strength test pressure are disconnected.


The pressure testing manifold is 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.


Buried pipeline are adequately bermed or covered to anchor the line during pressure test.

SAES-L-450 Appendix C

Pressure gages and pressure recorders are calibrated within one (1) month before the test. Check stickers at the time of the test.

SAES-A-004,Para. 7.1.5 (a)

Paddle or spectacle blinds shall be used to isolate test sections. Safety of test "implements" has been checked (SAIC-A-2009)


A bleed valve readily accessible is provided in case immediate depressurization is required.


C23

C24 Reconnect

C25

C26 As Referenced










EVALUATE CLEANING (PROCEDURES) & PROPOSED LAY-UPS: For pipe up to 12-inch NPS - flushed clean of loose scale/debris or scraped prior to commencement of pressure testing per procedure Note 1: If flushing was done with valves in line, cavity cleanliness is highly suspect where no low point drains exist. Verify post-test removal of scale/debris/water in low points (Check valve cavities). Random verification involves Inspection of valve cavities. This is a standard comment or addition to the punchlist. Note 2: Internal Cleaning procedure for pipe size larger than 14 inch shall be submited for review and approval) See SATIP-L-108. Flushing Cert is available in the test package for review


Water removal & Preservation & LAY-UP (Follow-up)

All pressure containing components of pipeline, except instruments that may be damaged by the test pressure, were physically verified to be included in test using P&ID, ISOs (Pressure Test Diagram)


PRE-TEST SPEC CHECK SEE ATTACHMENT 4.

Inspection Excellence

Verify correct specs all special

processes

Use SAIC-A-2011 along with this checklist (inspection efficiency) whenever walkdown is done on the same day as press. testing

REMARKS:

1. SAES-A-004, General Requirements for Pressure Testing, (30 March, 2005) 2. SAES-L-105, Piping Material Specifications, (30 March, 2005) 3. SAES-L-108, Selection of Valves, (30 March, 2005) 4. SAES-L-110, Limitations on Pipe Joints and Components, (30 March, 2005) 5. SAES-L-150, Pressure Testing of Plant Piping and Pipelines, (30 September, 2003) 6. SAES-L-350, Construction of Plant Piping, (30 September, 2003)7. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (30 September, 2003) 8. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005)




SAUDI ARAMCO Date :

Location: Unit :




Re-instatement Checklist (Form) SATR-A-2011 25-May-05 MECH-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR


DRAWING NUMBER (P&ID/ISO) / REV. No. PRESSURE TEST DIAGRAM NATURE OF TEST WORK PERMIT REQD?

SAUDI ARAMCO TIP (SATIP) NUMBER SATIP Activity No. SUPPORTING SAIC Number SAIC QR No.

Reference


Test Performed Successfully and Results are Acceptable:



Name, Initials and Date:Witnessed Test Work / Rework May Proceed



System No.

Notes: 1) This Form shall be used in conjunction with an applicable Reinstatement Procedure for all Test Packages (SAEP-1160). 2) "B" items from Pre-Test Checklist are cleared after testing during re-instatement to close & certify Test Pkgs. 3) Any items not completed during the re-instatement shall be added to Mechanical Completion Punchlists and submitted to Saudi Aramco (FEIL). ETC = Estimated Time of Completion (Affects lay-up selections)

Item#

Description (Use with applicable Re-Instatement Procedure)

Origi-nator

ETC(Note 3)

Verified complete

by QC

Concur(PID)

Certify Test Package Complete

All above items have been completed on Reinstatement per procedure and test package is certified complete: BK 1/2/2005Remarks:

Technician Performing Test* PMT Representative

Name, Title, Department,Company, Initials and

Date:

Name, Sign and Date: Quality Record Approved: T&I Witnessed QC Record Reviewed Work VerifiedName, Organization,

Initials and Date:


SAUDI ARAMCO Date :

Location: Unit :




Final Piping Punchlisting (Piping Re-Instatement) SAIC-L-2022 1-Dec-06 PIPE-






ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A Y/N RE-INSP DATE

NOTE: See " REMARKS" for instruction of use of this checklist.

A Documentation:

A1 Y

A2 Y

A3 Y

A4 Y/N

A5 Y

B P&ID Check/Walkthrough:

B1 Y

B2 Y

B3 N

B4 N

B5 Y

B6 Pressure gages installed are of the same range as shown in the P&ID. Y

B7 Y

System No.

ITEM No.

Mechanical Scope of Works are complete. Any exceptions were identified and listed in the Sytem punchlist.

GI-2.710Para. 4.1.1.2

Test and Inspection Plan (SATIPs) and Inspection Checklists for field installation as detailed in SATIP-L-350-01 have been verified to be complete and accepted.

GI-2.710Para. 4.1.1.2

All non-conformance reports and worksheets have been resolved to the satisfaction of Inspection Department.

GI-2.710Para. 4.1.1.4

All log book entries have been resolved to the satisfaction of Inspection Department.

GI-2.710Para. 4.1.1.4

All piping fabrication documents, inspection record books and are available for review.

GI-2.710Para. 4.1.1.6

All piping components are installed in their respective locations as shown in the P&ID. (i.e: piping, removable pipe spools, valves, vents, drains, spectacle plates, blinds, flange spacers, etc)

P&ID #____________

All in-line equipment & Instruments are installed in their respective locations as shown in the P&ID. (i.e: Strainer, meter tube, straightening vanes, flow meter, orifice fitting, Pressure Indicators, Temperature, temperature indicators, sample probes, etc)

P&ID #____________

Header pipe are stenciled with the following:a. Flow directional arrows and fluid service b. Line designation number, size, class and specification

SAES-L-350Sec. 20 a & b

Identication are stencilled on major components of the PIPING such as but not limited to : (Note: Identification shall follow Equipment identification number designated on the P&ID) a. Identification number for metering skid b. Identification number for prover when installed b. Strainer c. Flow element/flow meter d. Control Valves e. MOV's f. Relief Valves

SAES-L-350,Sec. 20

Installed Relief Valves were verified and the corresponding Form 3099A signed.

SAES-J-600,Sec. 10

P&ID #____________

Delete if covered by

Instrumentation

Pressure gages are installed with block and bleed valves. (The bleed valve shall be plugged.)

SAES-J-200'Para. 6.1 & 6.4


Instrumentation

B8 Y

B9 N

B10 Y

B11 Flow direction of check valves follow the process flow direction. Y

C Piping:

C1 Y

C2 Pipe clamps are tightened and in full contact with the pipe. Y

C3 Weld attachments to the pipe are seal welded. Y

C5 Jack screw bolts installed in flanges with spectacle plates. Y/N

C6 N

C7 N

C8 Pressure test of field installed piping and components are complete. Y

C9 All nuts and bolts of flange connections are fully engaged. Y

C10 Y

C11 Y

C12 Y

D Pipe Supports

D1 Y

D2 Y

D3 Y

D4 Y

D5 All pipe supports are in full contact with the support and carries the load. Y

D6 Travel stops of spring supports are removed after hydrotest. Y

Temperature Gages installed are of the same range as shown in the P&ID.

P&ID #

____________


Instrumentation

Thermowells are provided with chained plug and plug installed where temperature indicators are not provided. (Std.Dwg.AB-36019)

SAES-J-400,Para. 5.2.5


Instrumentation

Flow direction of Control valves and globe valves follow the process flow direction.

P&ID #____________

P&ID #____________

Pipe are resting fully on pipe supports. Shims are installed and seal welded to pipe supports to maintain contact where required.

SAES-L-350,Para. 14.2.2

SAES-L-350,Para. 14.2.2



A 6 mm weep hole shall be drilled for all dummy supports and shall be located near the base plate for all vertical dummy supports, and near the run pipe at 6 o'clock position for all horizontal dummy supports.

SAES-L-350,Para. 13.2.3

Atmospheric drain and vent valves shall be provided with a plug or blind on the discharge side.


GI-2.710-6,Item 4a

GI-2.710-6,Item 1.j.

Flange joints for piping Class ANSI 600# and above were verified to be tightened using the applicablr Torque procedure.

GI-2.710-6,Item 1.j.

A minimum clearance of 50 mm shall be provided for inspection and freedom of pipe movement between above ground piping crossing with any structure (including pipe support structure). This clearance is also required for above ground piping crossing with another pipe.


Branch connections, 4 inch and smaller, including drain and vent valves and drip legs of all sizes, are not located at a horizontal distance less than 610 mm (24 inches) from any fixed obstruction.


Pipe guides are installed at locations as shown in the AFC isometric drawings.

SAES-L-310,Para. 15.2.1

Details of the installed pipe supports conforms with the Pipe Support Detail per project specification.

AFC Drawings

Intermediate anchors or axial line stops are provided for above-ground unrestrained piping between and/or at the center of expansion loops or offsets.

SAES-L-310,Para. 15.2.2

Axial line stops and guides shall be provided for above ground unrestrained lines subject to slug forces in services listed below.• Two-phase flow lines• Liquid intermittent lines, such those used to control liquid level in the drums• Pressurized drain lines• Relief and blow-down lines• Flare lines• High-pressure gas lines

SAES-L-310,Para. 15.2.3

SAES-L-310,Para. 14.2.2

SAES-L-310,Para. 14.4.4

D7 Y

E Structural Items:

E1 N

E2 N

E3 Y

E4 Y

F Painting:

F1 Y/N

F2 Scope of Work N

F3 Y

F4 N

F5 Scope of Work Y


1. G.I.-2.710, Mechanical Completion and Performance Acceptance of Facilities, (13 July, 2004)

2. SAES-L-310, Design of Plant Piping, (30 September, 2003)

3. SAES-L-108, Selection of Valves, (21 December 2005)

4. SAES-M-001, Structural Design Criteria for Non-Building Structures, (30 June, 2004)

5. SAES-L-350, Construction of Plant Piping, (30 September, 2003)

6. SAES-J-200, Pressure, (31 May, 2003)

7. SAES-J-400, Temperature, (31 May, 2004)

8. SAES-J-600, Pressure Relief Devices, (30 March, 2005)

9. SAES-B-054, Access, Egress, and Materials Handling for Plant Facilities, (15 March 2006)

10. SAES-B-067, Safety Identification and Safety Colors, (30 November, 2003)







The pipe shall not be used to support other pipes and structures without an appropriate analysis.

SAES-L-310,Para. 16.1.2

Access is provided for equipment regularly operated or maintained or operated in an emergency, such as valve hand wheels, instrumentation, controls, and their associated manifolds,

SAES-B-054,Para. 4.2

Edges of all tightly contacting surfaces of steel structures are seal welded.

SAES-M-001,Para. 7.1.3.3

Access gratings are firmly anchored with a minimum of 2 fasteners at each support with a minimum of 4 fasteners per panel. (Note: Non-compliance shall be identified as "YES" item in the Facility Exception Item List for the MCC.)

12-SAMSS-007,Para. 6.1.16

Lifting equipment were tested and sticker issued by ID Crane Inspection Rep.

G.I-2.710-6Item 1.i.

External coating on piping is complete and conforms with the project coating requirements. (Note: Pipes, vessels, valves, and related structural supports shall be painted a neutral background color such as aluminum, gray, or black per SAES-B-067, Para.4.1.1)

SAES-L-350Para. 21.1

Coating on structural items is complete and conforms with the project coating requirements.

Safety yellow-and-black stripes are painted on obstructions that present bump hazards. (concrete supports at the base of stairways or ladders, passageway pinch points, unguarded edges, tripping hazards). Stripes shall be 100 mm wide.

SAES-B-067,Para. 4.2.3 a

Lifting equipment and devices shall be painted safety yellow and clearly marked with the rated capacity of the equipment in Arabic and English in metric tons.

SAES-B-067,Para. 4.4

Insulation is complete per applicable SATIP-N-001-01 or SATIP-N-001-02

General Notes:1. Any Item marked as "Fail" requires to be identified with the specific description and location of the descripancy/violation and shall be listed in the Re-Instatement Punchlist Form (SATR-A-2011).2. Column "Y/N" is used to pre-determine each respective item as required for start-up (Y), or not required for start-up (N). Final designation of "Y/N" items will be at the Mechanical Completion Punchlisting by Saudi Aramco Inspection.3. This Checklist along with the Re-Instatement Punchlist Form (SATR-A-2011), with or with out cleared items, shall be submitted to Saudi Aramco on or before the requested time for Mechanical Completion Punchlisting.4. Where blank lines are provided, please indicate the applicable requirements or actual data/information required for verification.

REMARKS:


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