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INDEX

Section No.

1.0 Scope

2.0 References

3.0 Definitions

4.0 General Requirements

5.0 Specific Testing Procedure / Requirements

6.0 Preparation of Test Packages

7.0 Preparation of Hydrotesting

8.0 Cleaning / Flushing of Spools or Piping System

9.0 Method of Hydrotesting

10.0 Reinstatement of Lines

11.0 Repairs / Repair Procedure

12.0 Safety Precaution

13.0 Records and Documents

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1. Scope

1.1 This procedure defines mandatory general requirements governing flanged-type

spools and in-situ pressure testing of new and existing piping systems and plant
piping. Specific requirements are covered in the specific Saudi Aramco Engineering
Specifications applicable to that piping system or plant piping. This procedure shall
be in compliance with ANSI / ASME B31.3 Process Piping.
1.2 This procedure does not cover pressure testing of new, shop fabricated equipment
such as vessels, tanks, heat exchangers and skid mounted piping which is purchased
in accordance with the applicable SAMMS.
1.3 Leak test normally conducted by operations during start-up, commissioning and T &
I, of the facilities in accordance with approved plant operating procedures, which are
excluded in this procedure.
1.4 Revalidation pressure test for tie-in spools in the existing piping systems shall
requires as well approval from the Manager of Inspection Department and Manager
from Saudi Aramco Project Inspection Division (PID)

2. References

The Selection of material, equipment and the design construction, maintenance,

repair of piping equipment and facilities required by this procedure shall comply with the
latest edition of the references listed below, unless otherwise noted. IFC drawings shall
be attached to the package and all other information essentially for the smooth operation
of the pressure test.

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2.1. Saudi Aramco References / Saudi Aramco Engineering Procedures / Saudi

Aramco Engineering Standard.

SAES-A-004 General Requirements for Pressure Testing

SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedures

SAES-A-327 Disposal of Wastewater from Cleaning, Flushing, and

Dewatering Pipelines and Vessels
SAES-A-005 Safety Instruction Sheet

SAES-L-150 Pressure Testing Pipelines and Plant Piping

SAES-S-020 Industrial Drainage and Sewer

SAES-S-040 Saudi Aramco Water Systems

SAES-S-060 Saudi Aramco Plumbing Code

SAES-S-070 Installation of Utility Piping System

2.2. Saudi Aramco Materials System Specification

01-SAMMS-010 Fabricated Carbon Steel Piping

04-SAMMS-048 Valve Testing and Inspection Requirements

2.3. Saudi Aramco Form and Data Sheet

Form 2642-ENG Pressure Test Report Form

2.3. Saudi Aramco General Instructions

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 GI-0002.102 Pressure Testing Safely

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2.4. Industry Codes and Standards

American Society of Mechanical Engineers
ASME B31.3 Process Piping
2.5. Schedule Q
2.6. Quality Plan

3. Definitions

Hydrostatic Test: A pressure test to ensure strength or tightness of the system. It is a

strength test at an internal pressure determined in accordance with SAES-A-004 and the
applicable Code to verify the integrity of the piping systems or equipment for service at
the design pressure.
Pneumatic Test: A pressure test conducted using air or other approved gas as the test
medium or in conjunction with liquid.
Pressure test: A test conducted to piping or equipment by subjecting it into an internal
pressure using liquid or gas to ensure strength or tightness of the system at the test
pressure.
System test: An in-situ pressure test applied to a group of piping and equipment tested as
a system.

4. General Requirements
4.1 General Instruction GI-0002.102 Pressure Testing Safely shall be followed during
pressure testing.

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4.2 Pneumatic testing is not permitted without the written approval of the Manager,
Inspection Department. Unless specifically allowed by the reference Saudi Aramco
SAES or SAMMSs. All NDE shall be completed and accepted before conducting
hydrotest.
Pneumatic testing with air of piping systems or equipment, which have been in
flammable service, shall be concurred by the Manager, Loss Prevention Department.
The test procedures shall include cleaning / purging procedures to avoid explosive
flammable air mixture.
4.3 The effect of the static head of the testing liquid shall be considered when
determining the effective test pressure of any elements within a tested system.
4.4 Except where noted here or in the specific referenced standard in Section 6, the test
pressure shall be maintained for a sufficient time to determine that there are no leaks.
All weld joints shall be exposed for visual leak detection during pressure test.
4.5 Protection from Overpressure / Control Pressurization
All systems (piping and equipment) while being pressure tested shall be protected
from being over pressured by the following.
4.5.1 Relief valve(s) of adequate capacity set to relieve at 5% above the Hydro
test pressure shall be installed. Sizing of these relief valves used for testing
shall follow the requirements of API RP 520, Part 1. the relief valve(s)
shall be tested, dated, and within one week prior to the pressure test for
new construction projects, and within one month for maintenance
operations.

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4.5.2 In addition to the pressure-relieving device, a bleed valve shall be
provided to protect the piping and equipment from overpressure.

The bleed valve shall be readily accessible in case immediate de-

pressurization is required.
4.5.3 An isolation valve shall be provided between the pressure-testing manifold
the system being tested. The isolation valve shall be rated for the manifold
test pressure when in closed position.
4.5.4 Before employing the pressure testing manifold in the actual system
pressure test, it shall be separately pressure tested to at least 1.2 times the
systems test pressure but not less than the discharge pressure of the pump
used for the pressure testing.

4.6 Test Procedure

4.6.1 Pressure test diagrams and test procedures shall be prepared by the
responsible engineering group and made available to Inspection prior to
conducting the test. The test diagram and procedures shall include the
limits of piping (including test manifold) and equipment included in each
pressure test, test pressures, test temperature, test fluid, line flushing
requirements, and safety precautions.
4.6.2 A request of NDT in lieu of pressure testing shall be submitted for
approval as permitted in the specific SAES listed in section 6. A sample
form will be provided as an equivalent that shall be processed prior to
NDT.

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4.7 The requirements for leak tests and service test and service during initial start-up and
T & Is shall be as follows:
4.7.1 New system after strength and tightness test and prior to initial start-up.
4.7.1.1 For systems with maximum operating pressure greater than 6.894
Mpa (1000psi), a leak test with inert gas, followed by a service
test, shall be conducted at the maximum operating pressure of the
piping system. Oil flow lines, trunk lines, test lines and water
injection lines are excluded from the requirements.
4.7.1.2 For systems with maximum operating pressure less than 6.894
MPA (1000psi), a leak test with inert gas or steam shall be
conducted at the available inert gas or steam system pressure (not
exceeding the maximum operating pressure), or damage as
recommended by responsible Operation Engineering Unit,
followed by a service test at normal operating pressure of the
piping systems. When inert gas or steam is not available, the
service test will satisfy the leak requirement.

4.7.2 Existing systems after T & IS:

4.7.2.1 For systems with maximum operating pressure greater than 6.894
MPA (1000psi) which are in hydrogen service or in sour service
with hydrogen sulfide concentration higher than 0.1 mole%.

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4.7.2.2 For all other systems and pressure, a leak test with inert gas or
steam shall conducted at the available inert gas or steam system
pressure (not exceeding the maximum operating pressure), or at
pressure as recommended by responsible Operation Engineering
Unit, followed by a service test at normal operating pressure of the
piping systems. When inert gas or steam is not available, the
service test will satisfy the leak test requirements.
4.7.2.3 Procedures for both leak test and service test shall address, to the
extent possible, the safety precautions provided in GI-0002.102
Pressure Testing Safely.
If the drop in ambient temperature may cause the test medium to freeze
during the test, appropriate precautionary measures must be taken to
protest the equipment or piping system.
5. Specific Testing Procedure / Requirements
This section specifies in details which piping or equipment that shall be pressure tested
and provides the specific applicable standard. It also defines any specific exemptions.
5.1 Plant Piping
Pressure testing of plant piping shall be in accordance with SAES-L-150

5.2 Potable Water Piping

Potable water piping inside buildings shall be tested in accordance with the
requirements of the Uniform Plumbing Code (UPC). Exceptions to UPC
requirements are listed in SAES-S-040.

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Potable water piping outside of the building shall be tested in accordance with
the requirements of SAES-S-40.
5.3 Utility Piping System
Utility piping systems, including irrigation piping and water distribution
mains, shall be tested in accordance with SAES-S-070.
5.4 Industrial Drainage and Sewers
Industrial drainage and sewers shall be tested in accordance with SAES-S-
020.
6. Preparation of Test Packages
6.1 Carefully study the P & ID drawings and identify isometric drawing shall be
reviewed jointly by PMT, MFH, CZFP & APOD to ensure that all the tie-ins and
hydrotests are well coordinated to minimize the shut-down of facilities prior to
finalizing the hydrotest diagrams and packages.
6.2 MFH will prepare the Pressure Test Packages and Saudi Aramco will issue the
approved Test Package after the review and approval by Saudi Aramco. MFH
with the coordination of Saudi Aramco and will prepare the pressure test diagram
for each test pack showing the location of the isolation points or valve location,
test manifold, check valves, pressure relief valves and pressure gauges. It should
also identify the pressure rating of PRVs and shall be 5% above the maximum
test pressure. The capacity of the pressure gauges should be at least 4-times the
required test pressure.
6.3 MFH shall identify the location of the test limits in agreement with Saudi Aramco
and SAPMT if piping system is completely installed at site. If spools are in flange

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type system, these can pressure tested at the shop and will be witnessed by
Saudi Aramco and SAPMT.
6.4 MFH shall provide the required blind or slip blind rating list and do all the
required fabrication. MFH to ensure that the required slip blind rating list
is in compliance with the pressure rating design and as per Saudi Aramco
Engineering Standards.
6.5 Saudi Aramco to finally issue the approval of pressure Package after the
review of SAPMT.
7. Preparation for Hydrotestesting
7.1 If fabricated spools cannot be pressure tested at the shop, ensure that all of
the weld joints are uncoated including field weld joints. Coating of weld
joints on spools shall be done only after the completion of pressure test.
Fabricated spools can be painted leaving all weld joints uncoated.
7.2 Flushing of new piping spools or piping systems shall be done prior to any
pressure testing to internal parts of each spools are clean and free from any
foreign debris or materials.
7.3 Prepare the records for all fabrication, erection, inspection, NDE and
PWHT (when required) for each test packages. Check for the completion
of the above activities on the lines to be pressure tested.
7.4 Pre-punch list the lines prior to pressure testing for items that can be
installed after the completion of the pressure test, and after test
completion, identify any missing items and activities and punch list it
again prior to MCC (Mechanical Completion Certificate.).

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7.5 Identify the required sizes of blinds or slip blinds and their ratings that
shall be installed on the reference test limits for pressure test. PMT is
requested that the installed slip blinds are verified and signed by APIU
prior to pressuring of the piping circuits.
7.6 Prepare a list of piping pipe supports prior to and after pressure test. All
spring supports shall be locked prior to pressure test and unlocked on
completion of pressure test.
7.7 Isolate equipment to piping such as pumps, pressure relieving devices,
control valves, pressure indicating gauges, etc., which should not be
subjected to pressure test. Isolation by installing a dummy spools,
temporary slip blinds or blinds are acceptable to Saudi Aramco, SAPMT.
7.8 MFH QC shall raise an RFI for the joint inspection and walk through of
the lines with Saudi Aramco, Saudi Aramco SAPMT prior to the approval
for pressure testing.
7.9 Ensure that the pressure gauges and pressure relief valves have been
calibrated and the calibration certificates are available for verification by
Saudi Aramco and Saudi Aramco Project Inspector. Pressure guage
instruments should have a valid calibration certificate and a sticker is
placed to the gauge. Pressure gauges shall be calibrated every one (1)-
month while pressure relief valve shall be tested, dated and tagged within
one week (7-days) prior to the hydrotest for new construction projects, and
within one (1)-month for the maintenance.
7.10 The pressure test manifold in the actual system pressure test shall be
separately pressure tested to at least 1.2 times the system test pressure.

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8. Cleaning / Flushing of spools or Piping Systems

8.1 Extra care shall be exercised to ensure all pipe spools are internally clean prior to
installation.
8.2 All new piping spools or systems with pipe sizes up to 12-inches NPS shall be
flushed clean to remove all loose scale and debris or scraped prior to pressure
testing.
8.3 All new piping spools or systems with pipe sizes of 14-inches and larger shall be
internally cleaned individually.
8.4 Clean internally by air blowing and rag cleaning for all piping spool prior to
installation.
8.5 After internal cleaning, cover the piping ends with polyethelene sheets cover to
preserved cleanliness.
8.6 To flush installed piping system, set-up pump and its manifold with pressure hose
connected to the lines to be tested. All vents drains and valves shall be car sealed
open.
8.7 Flush the line by filling from the lowest point to the highest point. When the
flushing is done suitable arrangement is to be made to ensure that dirt, scale,
debris, etc. is not flush into motors, pumps, equipment or dead end of the
pipework. Flushing shall be discontinued when the test fluid becomes clear.
8.8 The water to be used for pressure testing shall be of potable quality and shall be
free from dirt, dust and foreign particles. Water to be used for stainless steel shall
not be containing more than 50 ppm of chlorides. (if stainless steel line is to be
pressure tested.)

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9. Method of Hydrotesting
9.1 Start filling the system with clean water keeping open the vents to eliminate air
traps. Close the vents when the piping system has been filled with water, and
when the discharge of water from vents is free from water bubbles.
9.2 Install pressure gauges, as shown on the pressure test diagram, with one pressure
gauge at the highest point in the system.
9.3 Open the valve at the gauges and apply the pressure at the rate of 7 bar/min.
maximum, and the required test pressure shall be applied into 3-stages.
9.4 See attached sample sketch of a typical pressure test diagram.
9.5 The system shall be pressurized to it required test pressure rating to be obtained
from APOD & PMT (when it is not specified, test pressure is = design pressure x
1.5) and held for a minimum of 30 minutes, or until such time the visual
examination for all weld joints is completed.
9.6 Inspect all the weld joints for any possible leakage and check the pressure gauges
for any pressure drop.
9.7 Ambient temperature limit during pressure testing shall be between 10 oC and
50oC.
9.8 Both relief and bleed valves are required for all piping and equipment under test
(SAES-A-004) para.5.5).
9.9 The inspector shall witness and accept the flushing procedures prior to
commencement of pressure test. (SAES-A-004 para. 7.1.2).
9.10 Filling and draining of the system under test shall be performed carefully to
prevent entrapped air or formation of vacuum. (SAES-A-004, para. 8 and 9).

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9.11 Firewater systems shall be tested for 4 hours in accordance with SAES-B-017.
9.12 Pressure sewers shall be tested under the same conditions as for pressure piping.
9.13 Buried lines should be tested before backfilling. In case where a trench has been
backfilled prior to a pressure test, a 24-hours pressure/temperature recorded test is
required per SAES-L-150.
9.14 Welded connections that are impractical to pressure test may be 100% inspected
by NDE in lieu of a pressure test (SAES-A-004, para. 3.67.2). the Appendix of
SAES-A-004 shall be submitted to the applicable approval authority at least 24
hours prior to actual test.
9.15 Safety requirements described in SAES-A-004 shall be reviewed and closely
followed when pressure testing.
9.16 MFH to provide the pressure test diagrams and procedures, for new projects to the
inspector conducting the test. Refer to SAES-A-004, para. 5.6.1 for details of
these documents.
9.17 Piping detail drawings for end connections, branches, crossings, etc. including
pipe support and anchor details shall be available for review and approval.
9.18 Highlighting any special features or precautions, tie-in temperature range, any
other test required, lay-up and commissioning as applicable.
9.19 Perform pressure test as detailed below:

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-Pressure test lines shall be carried out using potable water with the addition of
rust inhibitor (when required). Maximum chloride content shall not exceed
30ppm.
-Test shall be carried out at ambient temperature (10oC and 35oC).
-Pressure gauges calibration and reading scale shall have a range to be between
and of the scale
-Employ the pressure test manifold in the actual system pressure test that had
been separately tested at 1.2 times the system test pressure but not less than the
discharge pressure of the pump used for the pressure testing.
-Expansion joints and spring hangers or spring supports shall be provided with
temporary restraint where needed to prevent excessive travel or deformation
under the test load.
-Filling and pressurizing shall be done on the upstream side of check valves in the
system or the flapper of the check valves shall be removed and replace back after
completion of the test. All test vents shall be open during filling.
-The test fluid shall be injected at the lowest point in the system to minimize
entrapped air.

Safety Procedure in Depressurization

-The release of pressure and draining shall be done on the downstream side of
check valves.
-The drain valve on the test manifold shall be slowly opened and to be closely
monitor the gradual reduction of pressure in the pressure gauges.

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-All test vents shall be opened before draining to facilitate draining and to prevent
formation of a vacuum. No test fluid shall remain in low spots.

10. Reinstatement of Lines

10.1 Upon completion of the test, the system shall be depressurized and the water shall
be drained. When draining, the vent valve shall be opened first before opening the
drain valve to prevent vacuum arising in the piping system. After the completion
of the testing, reinstall all isolated equipment / instruments. Install orifice plates,
control valves, flow meters and instruments on the system.
10.2 Remove all test spades, blinds, slip blinds and temporary dummy spools and join
the lines in the system. Install all permanent items previously pre-punch listed and
finally perform line checking to determine removal of blinds, unlocking of spring
support, installing valves and perform the remaining torquing of the flange joint.
10.3 A joint inspection of the piping system by MFH-QC, Saudi Aramco, SAPMT for
its completion in all respects shall be carried out and the signing of the final
documents will follow.

11. Repairs / Repairs Procedure

11.1 In case of leakage observed on any of the joint, it shall be repaired as per
approved procedures. The location of leakage shall be identified and marked with
clear color marker.
11.2 The whole system shall be depressurized and repair the weld joint by grounding
the location of leak.

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11.3 Perform dye penetrant test on the ground surface location of leak and identify any
form of surface defect or discontinuity.
11.4 Weld the prepared surface in accordance with the approved WPS. Perform 100%
NDE on this joint, MT/PT for socket weld joints and RT for butt weld joints.
11.5 The repaired joint shall be subjected to the same type of testing as specified for
the lines.
12. Safety Precautions
12.1 Work permit must be requested by MFH on pressure testing of piping systems or
plant piping, which will be under review, verification and approval, by Saudi
Aramco.
12.2 Barricade the area for pressure testing.
12.3 Place a signboard indicating the system.
12.4 Restrict entry for unauthorized personnel.
12.5 Check for the use of proper test pumps, manifolds, relief valves and pressure
gauges.
12.6 Check the lines to ensure that they are properly supported prior to the pressure
test.
13. Records and Documents
Below are the permanent quality records to be filled up after completion of the
pressure test;
Cleaning / Flushing Record
Pressure Test Records
Pressure Test Certificates

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