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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Verify Test Equipment (Safety Assessment)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2009
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?

ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Note TEST EQUIPMENT SAFETY ASSESSMENT (Notes 1-7) ... Perform along with SAIC-A-2011. 1 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 noncode 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). Test Manifold & Appurtanances (Piping, Fittings, Hoses) - Verify Test Package Content before Testing 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). Manifold Design Pressure Rating (Compare SIS for manifold & the system to be tested) exceeds system test pressure by 20%.

A1

G.I.-2.102, Para. 5.5

A2

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

Page 1 of 5

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Verify Test Equipment (Safety Assessment)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. B

ACCEPTANCE CRITERIA Verification of Actual Test Equipment Set-up (Manifold Arrangement) 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. 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) 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) Hoses are adequately rated, in good condition, safely arranged (tripping hazards) and protected from Heavy equipment traffic. 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 Test Relief Valve(s) 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) 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. 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. Pressure Gages and Recorders 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. 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). All gages have a range such that the test pressure is within 30% to 80% of the full range.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

B1

G.I.-2.102, Para. 5.2 b, SAEP-1160, Section 8

B2

G.I.-2.102, Para. 5.5 G.I.-2.102, Section 4 G.I.-2.102, Section 4 SAES-A-004 Para. 7.3

B3

B4

B5

C1

G.I.-2.102, Para. 5.5

C2

SAES-A-004 Para 5.5

C3

SAES-A-004 Para 5.5

D1

SAES-A-004 Para 7.1.5

D2

SAES-A-004 Para 7.1.5 G.I.-2.102, Sec.4 & SAES-A-004, Para 5.3 SAES-A-004 Para 7.1.5

D3

D4

Page 2 of 5

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Verify Test Equipment (Safety Assessment)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. E

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

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

E1

SAES-A-004 Para 5.6.1

E2

SAES-L-150, Para. 11.3

REMARKS: REFERENCE DOCUMENTS: 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)

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 5

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Verify Test Equipment (Safety Assessment)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. B

ACCEPTANCE CRITERIA Verification of Actual Test Equipment Set-up (Manifold Arrangement) 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. 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) 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) Hoses are adequately rated, in good condition, safely arranged (tripping hazards) and protected from Heavy equipment traffic. 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 Test Relief Valve(s) 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) 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. 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. Pressure Gages and Recorders 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. 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). All gages have a range such that the test pressure is within 30% to 80% of the full range.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

B1

G.I.-2.102, Para. 5.2 b, SAEP-1160, Section 8

B2

G.I.-2.102, Para. 5.5 G.I.-2.102, Section 4 G.I.-2.102, Section 4 SAES-A-004 Para. 7.3

B3

B4

B5

C1

G.I.-2.102, Para. 5.5

C2

SAES-A-004 Para 5.5

C3

SAES-A-004 Para 5.5

D1

SAES-A-004 Para 7.1.5

D2

SAES-A-004 Para 7.1.5 G.I.-2.102, Sec.4 & SAES-A-004, Para 5.3 SAES-A-004 Para 7.1.5

D3

D4

Page 4 of 5

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Verify Test Equipment (Safety Assessment)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-A-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. E

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

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

E1

SAES-A-004 Para 5.6.1

E2

SAES-L-150, Para. 11.3

REMARKS: REFERENCE DOCUMENTS: 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)

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 5 of 5