SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL

EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER

EQPT CODE

SYSTEM ID.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME

ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO USE ONLY

WORK PERMIT REQUIRED?

NOTES: 1) SAEP-1160 Section 8 details Minimum Test Package Requirements for Projects (Plant Piping, Pipelines, Equipment). Usage of SAEP1160 is mandatory when referenced by Sch Q for contracts with December 2005 cut-off dates and later. 2) Pressure Test Packages are (an integral part of) Test Procedures (See SAES-A-004 definition). Both Contract Sch Q & SAEP-1160 require a Pressure Testing Procedure, along with other procedures & a Test Package for effective/safe pressure testing work control. 3) Submit a single multiple document package as follows (30 days before the start of work per Sch Q) for Company approval: a) Three mandatory Pressure Test Procedures (as applicable) can be combined into one (Hydrotest, Pneumatic Test, Bubble Leak Test). b) Sample Test package with applicable QC records, Forms (per Attachment 1 of the Checklist and as listed below). c) A Re-instatement Procedure and Checklist (Utilize SAIC-A-2006 & SATR-A-2011 or QC forms meeting SATR minimum content). d) Pressure Test System Matrix (Modified Piping Design Line Index) per checklist as listed below. e) Pressure Test Package Database - Sample Status Report (per checklist as listed below). 4) Sample Test Package System ID & Status Report (Database). This is mandatory on large projects. Procedures shall detail Organizational Control responsibilities for test packages & have provisions for "lost packages" & other system controls for test packages from package design through system completion (MCC) and the QC certification process including turnover of records. 5) Pressure Test Matrix is a modified line list showing all systems and proposed pressure test design for SA approval. Reduce review time significantly & improve efficiency by performing a close review of Pressure Test Matrix & associated system information early on in major projects. "Critical Path" to MCC is nearly always Test Package Completion. Delays are often due to inefficiency, poor organization and planning, a lack of dedicated manpower solely for Pressure Test Package development, coordination, clearance, & inadequate test planning based on a system approach. 6) Test Package Format (Organization of Sections) shall be in the most efficient manner possible to eliminate package size and yet contain all applicable/important test information and documents needed for safe and correct system pressure testing. Copies of any procedures (Pressure Test, Leak Test, Reinstatement) shall only be provided with test packages on review for initial approval by Company. Procedure copies (Pressure Testing, GI-2.102, etc) shall be kept at test sites (test manifolds) with associated Safe Work Permits. Combining QC forms is encouraged. SATR use is required or alternatively, QC test reports shall contain SATR elements. Increase efficiency & eliminate waste. ITEM No. A A1 ACCEPTANCE CRITERIA Test Package Database & Format (Minimum Requirements) Test Package Minimum Content is per Attachment 1 Note: This checklist details SAEP-1160 specific requirements Pressure Test Matrix (Design) uses a modified system line list and contains specific proposed test information such as system names, line numbers, testing design data (system class, design/test pressures proposed), proposed test medium, test type (Hydrostatic or Pneumatic strength test, Service Test, Bubble Leak Test, flushing requirements, proposed Lay-up, special considerations/treatments, Chemical cleaning, mechanical cleaning, internal FBE coating, and other pressure test design considerations within Remarks section. Submit this Matrix along with a Sample Package Test Package Data Tracking System (Database) utilizes an elecronic format acceptable to Company and demonstates effective Test package tracking (system/line basis). Database is maintained & kept current & available at all times for Saudi Aramco review. Submit a sample "Database Status Report for Test Pkgs" Features of the database shall be compatible (linked = preference) with other SAEP-1160 required databases such as Welding & NDT to allow efficient test package clearance control practices on a system or line designation basis. Note: NDT & other special processes (PWHT, PMI, Coatings, etc) frequently hold up test package issuance. To improve efficiency, link databases to improve package coordination, prevent rework and retesting, and identify/target outstanding special process work SAEP-1160, Section 8 REFERENCE PASS FAIL N/A RE-INSP DATE

A2

SAEP-1160, Para. 5.1, Para. 5.2

A3

SAEP-1160, Para. 5.1, Para. 5.2

A4

SAEP-1160, Para. 5.1, Para. 5.2

Page 1 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Individual Test Packages consist of multiple sections: A) Flow Chart per Attachment 2 with an Index Page (Pkg Contents) B) Pre-Pressure Test (Punch List) Section with Checklists & Forms C) QC/NDE/Special Process Documentation (SAEP-1160 Database) D) Pressure Test Section (SIS, system info, test/calibration reports) E) System Cleanliness & Lay-Up & associated documentation F) Re-Instatement Procedure with Final Inspection (QC Certified) Six sections above can be broken down into additional sections as outlined in Pressure Testing Procedure & Sample Test Pkg. Test Package Flow Chart (Attachment 2) denotes responsible agencies for tracking & confirmation of various inspection reqmts. Index Page denotes Package Content and has specific signoffs for Quality Control/Assurance. This can be indexed by Section.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

A5

SAEP-1160, Section 8

A6 A7 B

SAEP-1160, Section 8 SAEP-1160, Section 8

Pre-Pressure Test Checklist (or Punchlist) Section contains the following: Pre-Pressure Test Checklist (Punchlist) Section meets the following requirements for specific content and field instruction: A) Specific SAIC-A-2010 - Pre-Pressure Test Checklist (Punchlist) for On-Plot Piping B) SATR-A-2007 - Pre-Pressure Test Check List (QC Form) Checklist shall cover all anticipated workscope items & provide adequate field instruction. Spec Check usage is recommended. P&ID & Isometric Drawings including a bill of materials/specs. An Index of applicable drawings is included in the test package. Reference all Line List numbers & corresponding dwg numbers QA/QC Documentation Section contains the following (as applicable) Weld Inspection Summary Sheet (Elements per SATR-W-2008) Note 1: This can be a single Sheet Database including all special process work in strict accordance with SAEP-1160 Sect. 6 Tables Note 2: Limited scopes (500 or less welds/project) are exempt and can use a Company approved hard copy tracking system. Detailed Weld Map (Isos for Plant Piping, pipelines use isos or sketch with detailed notes and legend as approved by Company) NDE Records (MT, PT, RT, UT) showing extent, sequence on NDE and selection meeting project specifications As-Built drawings as applicable to the workscope. Note 1: Test package SHALL show the actual system under test. Ensure piping modifications/revisions/dimensional changes are corrected by hand (red ink is preferable) on isos/sketches. Note 2: Corrections made by hand are acceptable (Initial & date). Note 3: "Provide As-Built drawings" can be listed as a "B" item Isolation Valve Test Certificates are available & utilize a unique Identification number whenever valves are field tested before their installation into the line for pressure testing. Flange Joint Assembly Inspection Report (SATR-L-2001). Internal Cleanliness / Flushing Report (SATR-A-2008) Verification of System Readiness for Testing (SAIC-A-2004) Checklists for test preparation and Test Equipment verification (SAIC-A-2009) Pressure Test Report Form (SATR-A-2001)

B1

SAEP-1160, Section 8

B2 C

SAEP-1160, Section 8

C1

SAEP-1160, Section 5.1

C2 C3

SAEP-1160, Section 8 SAEP-1160, Section 8

C4

SAEP-1160, Section 8

C5

SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8

C6 C7 C8 C8 C9

Page 2 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Calibration or Test certificates for the following test instruments as applicable: (Equivalent approved test reports are acceptable) a. Pressure gage and recorders (SATR-A-2002/2004) b. Temperature gage and recorders (SATR-A-2003/2005) c. Test Relief Valve/s (SATR-A-2006) d. Test Manifold (SATR-A-2001) e. Water Analysis (test medium) - (SATR-A-2014) Reinstatement Procedure QC form & Instructions. System Lay-up System Lay-Up Certificate Form (SATR-A-2009) Re-instatement and/or Final Assembly Final Punch List (By the Contractor) a. SAIC-L-2022 & b. SATR-A-2011

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

C10

SAEP-1160, Section 8

C11 E E1 F

SAEP-1160, Section 8

SAEP-1160, Section 8

F1

SAEP-1160, Section 8

REMARKS: REFERENCE DOCUMENTS: 1. SAEP-1160 - Process Controls for Capital Projects (June 7, 2006) 2. Schedule Q Pro Forma Contract (Contract Edition)

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

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

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

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

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

Y = YES

N = NO F = FAILED

Page 3 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003

1-Dec-06

MECH-

Attachment 1 -- SAEP-1160 Section 8 (Test Pkg Minimum Content)

Attachment 2 -- NEMA TC 2 (Type EPC-40-PVC)

Page 4 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003

1-Dec-06

MECH-

Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No
Test Pack Preparation

Engineering

Contractor QC

Pre-Test Punch Listing

(NOTE: Use form SATR-A-2007) Construction Contractor QC

Clear 'A' Items

Construction

Contractor QC

S. Aramco Pre-Test Punch Listing

SAPMT

PID

Proponent (By Request)

Clear S. Aramco 'A' Items

Construction

Contractor QC

SAPMT

PID

Flushing & Cleanliness

Construction

Contractor QC

SAPMT

PID

Proponent (By Request)

Pressure Testing

Construction

Contractor QC

SAPMT

PID

Proponent

System Lay-Up

Construction

Contractor QC

SAPMT

PID

Proponent (By Request)

Reinstate System Final Insp (Contractor)

Construction

Contractor QC

SAPMT

S. Aramco Final Insp for MCC

SAPMT

PID

Proponent

Page 5 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Individual Test Packages consist of multiple sections: A) Flow Chart per Attachment 2 with an Index Page (Pkg Contents) B) Pre-Pressure Test (Punch List) Section with Checklists & Forms C) QC/NDE/Special Process Documentation (SAEP-1160 Database) D) Pressure Test Section (SIS, system info, test/calibration reports) E) System Cleanliness & Lay-Up & associated documentation F) Re-Instatement Procedure with Final Inspection (QC Certified) Six sections above can be broken down into additional sections as outlined in Pressure Testing Procedure & Sample Test Pkg. Test Package Flow Chart (Attachment 2) denotes responsible agencies for tracking & confirmation of various inspection reqmts. Index Page denotes Package Content and has specific signoffs for Quality Control/Assurance. This can be indexed by Section.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

A5

SAEP-1160, Section 8

A6 A7 B

SAEP-1160, Section 8 SAEP-1160, Section 8

Pre-Pressure Test Checklist (or Punchlist) Section contains the following: Pre-Pressure Test Checklist (Punchlist) Section meets the following requirements for specific content and field instruction: A) Specific SAIC-A-2010 - Pre-Pressure Test Checklist (Punchlist) for On-Plot Piping B) SATR-A-2007 - Pre-Pressure Test Check List (QC Form) Checklist shall cover all anticipated workscope items & provide adequate field instruction. Spec Check usage is recommended. P&ID & Isometric Drawings including a bill of materials/specs. An Index of applicable drawings is included in the test package. Reference all Line List numbers & corresponding dwg numbers QA/QC Documentation Section contains the following (as applicable) Weld Inspection Summary Sheet (Elements per SATR-W-2008) Note 1: This can be a single Sheet Database including all special process work in strict accordance with SAEP-1160 Sect. 6 Tables Note 2: Limited scopes (500 or less welds/project) are exempt and can use a Company approved hard copy tracking system. Detailed Weld Map (Isos for Plant Piping, pipelines use isos or sketch with detailed notes and legend as approved by Company) NDE Records (MT, PT, RT, UT) showing extent, sequence on NDE and selection meeting project specifications As-Built drawings as applicable to the workscope. Note 1: Test package SHALL show the actual system under test. Ensure piping modifications/revisions/dimensional changes are corrected by hand (red ink is preferable) on isos/sketches. Note 2: Corrections made by hand are acceptable (Initial & date). Note 3: "Provide As-Built drawings" can be listed as a "B" item Isolation Valve Test Certificates are available & utilize a unique Identification number whenever valves are field tested before their installation into the line for pressure testing. Flange Joint Assembly Inspection Report (SATR-L-2001). Internal Cleanliness / Flushing Report (SATR-A-2008) Verification of System Readiness for Testing (SAIC-A-2004) Checklists for test preparation and Test Equipment verification (SAIC-A-2009) Pressure Test Report Form (SATR-A-2001)

B1

SAEP-1160, Section 8

B2 C

SAEP-1160, Section 8

C1

SAEP-1160, Section 5.1

C2 C3

SAEP-1160, Section 8 SAEP-1160, Section 8

C4

SAEP-1160, Section 8

C5

SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8 SAEP-1160, Section 8

C6 C7 C8 C8 C9

Page 6 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Calibration or Test certificates for the following test instruments as applicable: (Equivalent approved test reports are acceptable) a. Pressure gage and recorders (SATR-A-2002/2004) b. Temperature gage and recorders (SATR-A-2003/2005) c. Test Relief Valve/s (SATR-A-2006) d. Test Manifold (SATR-A-2001) e. Water Analysis (test medium) - (SATR-A-2014) Reinstatement Procedure QC form & Instructions. System Lay-up System Lay-Up Certificate Form (SATR-A-2009) Re-instatement and/or Final Assembly Final Punch List (By the Contractor) a. SAIC-L-2022 & b. SATR-A-2011

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

C10

SAEP-1160, Section 8

C11 E E1 F

SAEP-1160, Section 8

SAEP-1160, Section 8

F1

SAEP-1160, Section 8

REMARKS: REFERENCE DOCUMENTS: 1. SAEP-1160 - Process Controls for Capital Projects (June 7, 2006) 2. Schedule Q Pro Forma Contract (Contract Edition)

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

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

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

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

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

Y = YES

N = NO F = FAILED

Page 7 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003

1-Dec-06

MECH-

Attachment 1 -- SAEP-1160 Section 8 (Test Pkg Minimum Content)

Attachment 2 -- NEMA TC 2 (Type EPC-40-PVC)

Page 8 of 9

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005)

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of Test Package Preparation (Content, Format & Database)

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2003

1-Dec-06

MECH-

Attachment 2 -- TEST PACKAGE FLOW CHART Test Package (or Test System) No
Test Pack Preparation

Engineering

Contractor QC

Pre-Test Punch Listing

(NOTE: Use form SATR-A-2007) Construction Contractor QC

Clear 'A' Items

Construction

Contractor QC

S. Aramco Pre-Test Punch Listing

SAPMT

PID

Proponent (By Request)

Clear S. Aramco 'A' Items

Construction

Contractor QC

SAPMT

PID

Flushing & Cleanliness

Construction

Contractor QC

SAPMT

PID

Proponent (By Request)

Pressure Testing

Construction

Contractor QC

SAPMT

PID

Proponent

System Lay-Up

Construction

Contractor QC

SAPMT

PID

Proponent (By Request)

Reinstate System Final Insp (Contractor)

Construction

Contractor QC

SAPMT

S. Aramco Final Insp for MCC

SAPMT

PID

Proponent

Page 9 of 9