SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I.

Number Approved

GENERAL INSTRUCTION MANUAL 2.102

ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 07/18/2018 04/16/2013
APPROVAL PAGE NO.
SUBJECT PRESSURE TESTING SAFELY NYR 1 OF 18

CONTENTS

1.0 SCOPE
2.0 PURPOSE
3.0 REFERENCES
4.0 HAZARDS OF PRESSURE TESTING
5.0 PRINCIPLES OF SAFE PRESSURE TESTING
6.0 APPROVALS AND REVIEWS

SUPPLEMENT
2.102-1, CHECKLIST FOR PRESSURE TESTING SAFELY

1.0 SCOPE

1.1 This instruction provides, requirements for safe pressure testing of new and existing mechanical systems
including but not limited to piping, pipelines, pressure vessels, and power boilers (hereinafter called
systems). It applies to all pressure testing in Saudi Aramco facilities as well as pressure testing conducted
on or at locations directly engaged in Saudi Aramco projects, such as hydrostatic, pneumatic, and service
strength testing and tightness or leak testing, except as covered in Paragraph 1.2. Pressure testing
procedures and other documents issued by responsible organizations shall be consistent with this
instruction.

1.2 This instruction does not cover pressure testing of low pressure or atmospheric pressure storage tanks, or
equipment associated with drilling and workover operations such as blowout preventers, wellheads, wells,
and well tubulars, although portions of this instruction should be useful to those preparing pressure testing
procedures for such facilities.

1.3 This instruction is not intended to conflict with standards or codes used by Saudi Aramco such as those for
piping, pipelines, pressure vessels, and power boilers. Any such conflicts that arise shall be referred to the
Manager, Loss Prevention Department and shall be resolved in consultation with the Chief Engineer,
Engineering Organization, Dhahran.

1.4 For the purposes of this General Instruction, a proponent organization is the organization that is responsible
for oversight of the equipment/systems being tested (i.e., plant organization, project management team).

2.0 PURPOSE

The purpose of this instruction is to prevent injuries, fatalities, and property damage, environmental impact during
pressure testing by ensuring that:

(a) Pressure testing procedures are developed and that they include safety aspects of pressure testing.
(b) Pressure testing procedures are approved as required in this GI and that these procedures are followed by the
organization responsible for pressure testing.

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GENERAL INSTRUCTION MANUAL 2.102

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3.0 REFERENCES

- SAES-A-004, General Requirements for Pressure Testing

- SAES-A-007, Hydrostatic Testing Fluids and Lay-Up Requirements
- SAES-D-008, Repairs, Alterations and Re-Rating of Process Equipment
- GI 2.100, Work Permit System
- GI 6.102, Isolation, Lockout, and Use of Hold Tags
- GI 150.100, Hazardous Materials (HAZCOM) Communication Program
- GI 1021.000, Street and Road Closure: Excavations, Reinstatements, and Traffic Controls
- SAEP 310, Piping and Pipeline Repair
- SAEP 311, Installation of Hot Tapped and Stopple Connections
- SAEP 319, Inspection and Testing Requirements for Pressure Relief Devices
- SAEP 327, Disposal of Wastewater from Cleaning, Flushing and Dewatering Pipelines and Vessels
- SAEP 351, Bolted Flange Joints Assembly
- SAEP 1160, Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects
- SAES-L-150, Pressure Testing of Plant Piping and Pipelines
- American Society of Mechanical Engineers (ASME) Pressure Vessel Code, Sections I and VIII
- ASME PCC-2 Repair of Pressure Equipment and Piping

4.0 HAZARDS OF PRESSURE TESTING

Mishaps and failures during pressure testing may result in injuries, fatalities, business interruption, environmental
impact and property damage. The greatest potential hazard is an uncontrolled release of the large amount of
energy that can be stored in compressed air, gas or fluid, either in a pneumatic or a hydrostatic test. Other hazards
are associated with the handling of chemical additives, entering confined spaces, brittle fracture of materials, and
disposal of test mediums.

Uncontrolled releases of stored energy from compressed gases can take the form of catastrophic rupture.
Compressed fluids releases can result in high velocity streams of fluid that can cause piping and equipment to
move. The degrees of these hazards are determined primarily by the pressure and the volume of gas or fluid
involved.

The following are typical examples of unacceptable practices which may result in incidents:
- Striking or working on equipment, while it is under pressure, to stop leaks
- Improper or missing test equipment, such as testing without a relief valve, having an inadequately sized relief
valve, or having no pressure gauge(s)
- Omitting or changing steps in the test sequence such as failing to conduct a low pressure tightness test to check
for leaks prior to strength pressure tests at higher pressures
- Failure to vent air from the system prior to the test
- Use of gas as a test medium when water is appropriate
- Metal temperature below which the impact requirements are properly met by the material
- System not adequately supported to withstand the weight of the test medium during the test
- Pressure gauge(s), relief valve(s) and manifolds not calibrated and tested
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- Pressure gauge improperly located relative to pressurizing equipment causing errors in readings
- Appurtenances not adequate for the test pressure or not isolated from the test
- Pressure increased too rapidly (see section 5.2.3) to be controlled
- Relief valve inoperative because of a closed isolation valve
- Temporary test piping not rated for the test pressure
- No bleed valve provided on test piping
- Failure to pressure test the test equipment and piping prior to putting them in service
- Testing equipment with the test gauge located at the bottom of the equipment reading the test pressure,
including the head of test water
- Failure to open all vents before draining to facilitate drainage and to prevent formation of vacuum.
- Pressure gauge with inappropriate range.
- Metal temperatures near the ductile-brittle transition temperature
- Inadequate temporary equipment restraints
- Conducting pressure testing without first removing debris using brush/magnetic scrapers
- Failure to provide an isolation valve between pressure testing manifold and system being tested
- Failure to provide an isolation valve that is properly rated for the manifold test pressure when in closed
position
- Use of unapproved /improper bolt tightening method on temporary flange joints and test blinds
- Use of unapproved /improper assembly methods on threaded joint connections

5.0 PRINCIPLES OF SAFE PRESSURE TESTING

Supplement 1 of this GI Checklist for Pressure Testing Safely, shall be completed as required before, during, and
after the test. Before issuing the work permit, the checklist portion (before the test) shall be completed. This
checklist shall be kept with the work permit.

Employees engaged in pressure testing activities shall be knowledgeable and aware of all pressure testing and
safety requirements.

Pressure testing procedures shall be consistent with the following:

5.1 Before Start of Test

5.1.1 Assign Responsibility

5.1.1.1 The proponent organization (i.e., plant organization, project management) shall assign
persons to be responsible for:
(a) Preparation of the test procedures.
(b) Delivery of the approved test procedures to job sites.
(c) Hazard assessment and risk mitigation plan.
(d) Coordination and implementation of the pressure test in a safe manner.
(e) Inspection of the equipment as per (5.1.1.3)
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5.1.1.2 For major tests, representatives from Inspection Department and the responsible proponent
organization shall monitor testing.

Major tests include tests on: pipelines such as cross-country pipelines, submarine pipelines,
flowlines, trunklines, water injection pipelines, and gas lift pipelines; pressure vessels or
in-plant piping with an internal volume over 5.7 cubic meters (200 cubic feet); and power
boilers.

5.1.1.3 Before any test(s) are carried out, the proponent organization shall thoroughly inspect
equipment to ensure that appurtenances not adequate for the pressure test have been
isolated and the approved procedure is being followed.

5.1.2 Issue Written, Approved Procedures

5.1.2.1 Review historical documentation (e.g., equipment data sheets, inspection reports and safety
instruction sheets) for the equipment to be tested prior to writing and issuing test
procedures. The test procedure is to be reviewed and approved by the Saudi Aramco
proponent organization responsible for overseeing the testing.

5.1.2.2 The issuer of the procedure shall consult with plant process and/or instrument engineer to
review the test relief valve size and capacity to ensure it is adequate for the pressure test
and size of the tested system.

5.1.2.3 Written, approved procedures shall b6e provided to all concerned personnel at least two
days before testing, and be available at the job sites for pressure tests with a high hazard
potential, such as those on cross country pipelines of all kinds, plant piping, pressure
vessels, and power boilers.

5.1.2.4 Written procedures are not mandatory for tests on household utilities, irrigation sprinkler
systems, and low pressure, pneumatic leak tests on reinforcing pads and the annuli of weld-
plus-end couplings, per SAEP 310.

5.1.2.5 A written test package and test procedure shall be reviewed and approved per SAES-A-
004. The following information shall be included in the approved test package as a
minimum:
(a) Written test procedure
(b) A pressure test diagram or hydrostatic test diagram based on up-to-date system
P&ID’s.
(c) An approved test manifold arrangement compliant with SAES-A-004 Appendix B.
(d) The location of blind flanges and isolation valves, if any.
(e) The location of check valves (flappers should be removed, if necessary, prior to
testing).
(f) The location of the lowest rated component that determines the test pressure.
(g) The location of air vents, if appropriate.
(h) Relief valve size and set pressure.
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(i) The test medium.

(j) The test pressures.
(k) Special support requirements, if any, to take the weight of test liquid. Expansion joints
and spring hangars shall be fitted with temporary restraints.
(l) Chemical additives, if any.
(m) The test sequence.
(n) The minimum and maximum temperatures allowed, if appropriate.
(o) Details of inspection requirements for the equipment/system being tested.
(p) Areas to be kept free of people during the test and the required location of signage and
barricades.
(q) The location of warning signs and markings for the test areas, if appropriate.
(r) Work permits required, if any.
(s) The test medium disposal method.
(t) Additional or special personal safety equipment required.
(u) Safety Instruction Sheets and emergency communication required, and the methods.
(v) Vacuum valve size and set pressure, if any.
(w) The location of the filling point.
(x) Listing of correct sequence and necessary torque of all blind flange bolts and a
requirement to verify proper torque when bolting.
(y) The use of properly rated gaskets.
(z) The verification of compliance with the manufacturer’s rating specifications (e.g.,
quality, service use, pressure rating) for all gaskets and hoses used.

5.1.2.6 All important information on test pressures (e.g., timing and duration at every pressure rise
step) shall be recorded.

5.1.3 Use Proper Test Medium

5.1.3.1 Water shall be the pressure test medium for pipelines such as cross-country pipelines,
submarine pipelines, flowlines, trunklines, water injection pipelines and gas lift pipelines.

5.1.3.2 As stated above water is the test medium to be used for pressure testing primarily because
of the significant risks associated with using gases for pressure testing. All reasonable
alternatives shall be evaluated prior to considering gas pressure testing. Gas and hydro-
pneumatic pressure testing shall only be allowed per the approval of Inspection
Department. Air shall not be permitted as a pressure test medium in a system that was in
hydrocarbon service unless the system has been cleaned to avoid an explosive
hydrocarbon-air mixture.

5.1.3.3 The following shall never be used as pressure test mediums because they are extremely
hazardous:
- oxygen
- toxic gases

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- liquids above their flash points or atmospheric boiling points

- liquids above 66 deg. C (150 deg. F), except where necessary for pressure testing hot-
tapping connections on hot lines per SAEP 311, Installation of Hot Tapped and Stopple
Connections.

5.1.3.4 Steam, nitrogen or helium may be used as a pressure test medium only in tightness tests
and service tests.

5.1.3.5 When a liquid above 49 deg. C (120 deg. F) is used as a pressure test medium, such as the
use of aquifer water in testing water injection lines, personnel involved with the test shall
wear appropriate personal protective equipment to protect against exposure to hot liquid.

5.1.3.6 Non-toxic liquids other than water may be used for pressure testing if the operating fluid or
equipment can be adversely affected by water or freezing conditions. Refer to SAES-A-007
for more details.

5.1.3.7 Liquids with flash points below 54 deg. C (130 deg. F) shall not be used as a test medium.

5.1.4 Select and Treat Hydrostatic Test Water

To avoid corrosion and possible resulting failures from hydrostatic test water, the requirements of
SAES-A-007 for chemical treatment and selection of hydrostatic test water shall be followed.
Requirements of GI 0150.100 Hazardous Materials Communications Program shall be followed
regarding chemical treatment used for hydrostatic test water.

5.1.5 Use Appropriate Test Equipment

Appropriate test equipment shall be used to assure a controlled pressure increase, no overpressure,
and safe depressurization. The following are minimum requirements:

5.1.5.1 Tested relief valve(s) with a tag stamped with the word "TEST", the set pressure, and date
as required in SAEP 319. The relief valve shall have adequate capacity to prevent
overpressure during the test and shall have been tested in accordance with SAEP 319. The
relief valve shall be located in the system under test and near the test pump or other test
medium supply. The relief valve outlet shall be oriented to prevent equipment damage and
personal injuries should relief take place. No isolation valve shall be provided in the relief
valve's inlet or outlet with the following exception: if the relief valve is to be installed on
an existing valve connection and removing the valve is not practical because of fluid in the
system, this valve may be on the relief valve's inlet provided it is sealed open during the
test.

A plant process or instrument engineer shall approve the relief valve set pressure and
adequate relieving capacity. Consult with personnel in the Consulting Services Department
or Process & Control Systems Department, if necessary, to assure that the relief valve has
the proper set pressure and adequate capacity.

5.1.5.2 Two or more accurate and reliable pressure gauges with isolation and bleed valves to
permit safe replacement of the gauges, if necessary. The gauges shall have been calibrated
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within 30 days prior to the test and their range shall be such that the maximum test pressure
is within 30 to 80 percent of the full range. The calibration interval of the pressure gauges
shall be as per SAES-A-004. One gauge shall be located in the test piping such that it can
be read by the pump operator. The other gauge(s) shall be located in the system under test.

5.1.5.3 A blowdown valve for depressurizing the test piping and a valve to isolate the test piping
from the system under test shall be provided. Provide a readily accessible blowdown valve
on the system under test for the purpose of draining test fluid. The fluid shall be piped or
drained to a designated location, drain or area.

5.1.5.4 The test equipment is not required for tests on household utilities, irrigation sprinkler
systems, and low pressure pneumatic leak tests on reinforcing pads and the annuli of weld-
plus-ends couplings per SAEP 310, “Piping and Pipeline Repair.” For these tests, the test
equipment shall be selected by the person responsible for the test.

5.1.5.5 Any manifold for pressure testing purposes, either for permanent or temporary usage, shall
be tested separately from any other piping before it is used in conjunction with the testing
of any system. The test manifold shall be approved and maintained as per SAES-A-004.
The manifold shall be designed for and tested to a pressure not less than 20 percent above
the maximum test pressure to be applied on the system to be tested, except for the final
connection between the test manifold and the system under test, which may be designed for
and tested to the maximum system test pressure where a higher pressure is not feasible.

5.1.5.6 Specialized testing devices, such as direct spring assist units, shall be approved by the
Inspection Department and concurred by the Loss Prevention Department prior to use.

5.1.5.7 Where flexible test hose assemblies are used, those shall be restrained or shielded to restrict
whiplash hazards from failure. Such restraint may be achieved using whip-check cables.

5.1.6 Obtain Work Permits

Work permits shall be obtained for all pressure testing and associated work within restricted areas as
covered in GI 2.100, Work Permit System.

5.1.7 Isolate Equipment Not Adequate for Test Pressures

Appurtenances not part of the pressure test shall be blinded to exclude equipment which cannot
withstand the test pressure. Isolation valves designed to provide tight shutoff can only be used to
isolate equipment if it is not possible to use blind flanges, paddle blinds or spectacle blinds. If
isolation valves are used in lieu of blinds, provisions shall be made to ensure that no overpressuring
can occur in equipment that is not being tested, due to possible valve leak. The differential pressure
across the valve seat shall not exceed the seat test pressure during pressure testing and shall not
exceed the rated seat pressure during tightness test as per SAES-A-004 Para 5.13. Paddles or
spectacle blinds and other fabricated test items used to isolate test sections shall be at least the same
code class rating of systems under test or are supported by calculations.

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5.1.8 Prevent Overloads from Weight of Liquid

Portions of the system such as supports, vessels, piping, and foundations shall not be overloaded by
the weight of a test liquid. Prevent overloads by using such means as combining hydrostatic and
pneumatic tests for columns and providing temporary supports, where necessary. Prior to the start of
any such test, Consulting Services Department shall be consulted, to ensure that the system to be
tested can withstand the weight of the test liquid.

5.1.9 Handle Chemicals Safely

Safety Data Sheets or Chemical Hazard Bulletins as required by GI 0150.100 Hazardous Materials
Communication (HAZCOM) Program shall be reviewed for all chemicals handled such as corrosion
inhibitor, biocide, chlorine, and oxygen scavenger, and a written procedure to safely handle
chemicals during testing, and proper disposal of the chemicals after testing, shall be approved prior
to start of the work. Personal protective equipment shall be utilized as shown on these sheets and
bulletins.

5.1.10 Avoid Failure by Brittle Fracture

The metal temperature during a pressure test shall be in accordance with SAES-A-004, General
Requirements for Pressure Testing. To minimize the risk of brittle fracture during testing, the metal
temperature shall be maintained at least 30 degree F (17 degree C) above minimum design metal
temperature (MDMT) for piping or vessels. The test temperature should not exceed 120 degree F (50
degree C) or be below 59 degrees F (17C), unless there is information on the brittle characteristics of
the material indicating that a lower temperature is acceptable or a higher temperature is needed.

Positive Materials Identification (PMI) shall be conducted along with assessment by Consulting
Services Department (CSD) mechanical and materials engineers before testing pressure vessels with
unknown material impact properties to determine the minimum allowable test temperature.

5.1.11 Control Access to the Site

5.1.11.1 In plant areas and shops the test area shall be marked and warning signs shall be posted to
alert approaching personnel, where practical.

5.1.11.2 Personnel shall be positioned at plant sites to keep the test area clear of all people not
connected with the test, if necessary.

5.1.11.3 When pipelines, flowlines, or other systems outside of plant areas are tested, warning signs
as required in section 5.2.5.3 shall be placed at locations where people could be exposed,
such as road crossings.

5.1.11.4 Where a pipeline being tested transits under a road, the traffic shall be diverted or stopped
during the test, if practical. If this is not practical, personnel shall be posted at the crossing
to control traffic in the event of an incident affecting traffic safety. Follow GI 1021.000,
Street and Road Closure: Excavations, Reinstatements, and Traffic Controls for any
diversions.

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5.1.11.5 Where a road parallels within 30 m (100 ft.) of an aboveground pipeline being tested,
traffic shall be diverted or stopped during the test. If this is not practical, the responsible
area Loss Prevention office shall be contacted to assist in evaluating conditions that will
allow the test to be conducted safely. Traffic volume, time of day, potential traffic re-
routing or alternative routes are examples of variables that can be considered to facilitate
testing.

5.1.11.6 Scaffolding meeting Saudi Aramco requirements shall be provided to access elevated
pressure test locations.

5.1.12 Advise Saudi Aramco Affairs of Non-Saudi Aramco Exposures

If non-Saudi Aramco facilities will be exposed in a pressure test of Saudi Aramco facilities, the
proponent organization of the test shall inform the Saudi Aramco Affairs representative prior to the
test.

5.1.13 Notify Industrial Security of Tests Requiring Traffic Control

Notify Industrial Security of tests requiring their involvement in controlling traffic at the test site
such as tests of pipelines which cross roads.

5.1.14 Publicize Tests Interfering with Traffic

Publicize in the Saudi Aramco Weekly Highlights tests that will interfere with highway traffic.
Choose the time of the test so it does not occur during peak traffic hours, and follow GI 1021.000,
Street and Road Closure: Excavations, Reinstatements, and Traffic Controls.

5.2 During and After Test

5.2.1 Personnel working on a pressure test shall always wear the required personal protective equipment
(PPE). At a minimum, hard hats, safety glasses, face shields, gloves and safety shoes shall be worn
by individuals directly exposed to pressure testing hazards. Fire Resistant Clothing (FRC) is required
in areas where flammable/combustible materials are present. Additional PPE shall be selected and
used based upon the results of a documented risk-based PPE needs analysis, which shall consider the
exposure hazards, materials handled, and activities performed by personnel.

5.2.2 Remove Air Before Pressurizing (Liquid Test)

To reduce the amount of stored energy in tests where a liquid is the test medium, air shall be
removed from the system through vents at high points while the system is filled at the low point. In
pipelines equipped with scraping facilities, air removal can be achieved by using scrapers to displace
air with liquid.

5.2.3 Control Pressure Rise

5.2.3.1 The pressure rise during a pressure test shall be gradual and under control to allow time for
material to strain, and time for personnel to check for leaks.

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5.2.3.2 Do not exceed the following pressures until weaknesses have been repaired and leaks have
been stopped:
- Strength tests using a liquid test medium: 50 percent of the strength test pressure.
- Any tests using air or other gas as a test medium: 173 kPa (25 psig) or 50 percent of the
strength test pressure, which ever is the lower value.
- Units: 1 Bar = 100,000 N/m2 = 100 kPa = 14.5 psi

After preliminary checks for leaks at the above pressures, the pressure shall be increased in
steps with at least 10 minute holds at each step to permit inspection for leaks and
weaknesses.

5.2.3.3 In strength tests using air or other gas as the test medium, the pressure shall be increased in
steps no greater than one-tenth of the strength test pressure after reaching 50 percent of the
test pressure, as required in Section VIII of the ASME Pressure Vessel Code.

5.2.3.4 In strength tests using a liquid as the test medium, the pressure shall be increased in steps
no greater than one-fifth of the strength test pressure after the preliminary check at 50
percent of the strength test pressure.

5.2.3.5 Do not proceed to a higher pressure after each of the above steps until weaknesses have
been repaired and leaks have been stopped.

5.2.4 Depressurize Before Stopping Leaks or Repairing

Working on a system while it is under pressure is very hazardous because a failure could be initiated
by the work due to the addition of stresses in the material. Therefore, a system shall be depressurized
(with the exception of pressure due to a head of liquid) before any work is done to stop leaks or
repair weaknesses, including the tightening of bolts. In a tightness test, bolts may be tightened
without depressurizing if specifically approved by Inspection Department and concurred by Loss
Prevention in the written procedure.

5.2.5 Restrict Approach to the System

5.2.5.1 Systems never previously tested or with welds never previously tested are not to be
approached during the step-wise increase in pressure. The pressure, at which the system
under test, will be approached for close inspection shall be specified in the test procedure.

5.2.5.2 Personnel carrying out the test shall be provided with a safe place from which the progress
of the test can be observed and controlled.

5.2.5.3 Safety clearance distances shall be reviewed by the proponent organization for each
individual test, and safe clearance distances per 5.2.5.3.1 shall form part of the test
procedure. The restricted approach area shall be clearly marked with signage or other
appropriate barriers stating: “PRESSURE TESTING IN PROGRESS. ACCESS FOR
AUTHORIZED PERSONNEL ONLY”. Loss Prevention Department and Inspection
Department shall be consulted for advice, if necessary.

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5.2.5.3.1 If it is determined that pressure testing using a gas medium is the only available
alternative, safe distance calculations (safety clearance distances) shall be
performed per SAES-A-004, Appendix A, Pneumatic Test Checklist and ASME
PCC-2-2015, Article 5.1, Mandatory Appendix lll, “Safe Distance Calculations
for Pneumatic Pressure Test” and attached to the required test procedure.
Restricted approach areas shall be established based on safe distance
calculations.

5.2.5.3.2 When the spacing requirements described in 5.2.5.3.1 above are not achievable,
barricades shall be installed that are capable of withstanding the stored energy
calculated.

5.2.5.3.3 When high pressure hydrostatic testing is conducted, requirements for

additional barriers and approach restrictions shall be considered. For the
purposes of this requirement, high pressure is considered to be pressure in
excess of that allowed by the ASME B16.5 Class 2500 rating for the specified
design temperature and material group.

5.2.5.4 Only personnel involved with the test shall be allowed within the marked approach barriers
at any time during the test. No one shall approach the test area for a minimum of 10
minutes 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.

5.2.5.5 The test pump, if any, shall be located such that the pump operator will not be exposed to
danger in the event of a failure.

5.2.5.6 Systems laid up under inert gas pressure may also require restricted access. Organizations
that have overall responsibility for pressure testing shall ensure that stored energy of laid
up systems is calculated using ASME PCC-2 to determine if the level of stored energy
mandates safe distance restrictions.

5.2.6 Depressurize Safely

5.2.6.1 Upon completion of the test, the system shall be emptied in such a way as not to cause
vacuum and collapse. The depressurizing valve and piping shall be arranged for safe
discharge of the test medium upon completion of the test. Do not depressurize a system by
loosening bolts in a flange or by unscrewing fittings because this could lead to injury. Open
ended depressurization lines shall be secured at the discharge end (based on expected
forces) to prevent uncontrolled movement during pressure medium discharge.

5.2.6.2 Some systems, such as those with heat exchangers, may have to be depressurized slowly
and monitored with pressure gauges to avoid damage to internals such as tubesheets, which
may not be designed for the momentary differential pressure that could occur with a rapid
depressurization.

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5.2.7 Dispose of Test Mediums Safely

Written procedures approved prior to testing shall be followed for the disposal of test mediums
containing chemical additives for control of corrosion and bacteria. Consult with the Environmental
Protection Department for proper disposal methods per the requirements of SAEP 327, Disposal of
Wastewater from Cleaning, Flushing and Dewatering Pipeline and Vessels.

5.2.8 Follow Additional Safety Precautions

5.2.8.1 Allow the temperature of the test medium to equalize with the environment to the extent
practical before pressurizing the system to prevent abnormal pressure changes.

5.2.8.2 Attend the test pump at all times during the test unless isolated from the system.

5.2.8.3 Isolate the test piping with its isolation valve and bleed down its pressure when not needed
to avoid a possible failure.

5.2.8.4 Once the test is completed, do not leave the test system unattended. If it is left unattended,
then the vent has to be kept open to prevent temperature changes from causing an
overpressure or vacuum.

5.2.8.5 Keep the test relief valve installed until the test liquid has been drained to prevent possible
overpressure due to thermal expansion.

5.2.8.6 Drain liquid from a system slowly and with the vents open to prevent a possible vacuum.

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6.0 APPROVAL AND REVIEWS

Prior to testing, pressure testing procedures where required by this instruction shall be submitted by the party
responsible for the test to the responsible inspection group for review and concurrence. Approval by the Manager
of the Inspection Department shall be per SAES-A-004.

CONCURRED: ___________________________________ DATE: ________________

MANAGER
Inspection Department

CONCURRED: ___________________________________ DATE: ________________

CHIEF ENGINEER
Engineering

APPROVED: ___________________________________ DATE: ________________

MANAGER (A)
Loss Prevention Department

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SUPPLEMENT 2.102-1

CHECKLIST FOR PRESSURE TESTING SAFELY

This GI checklist shall be completed as required before, during, and after the test. Before issuing the hydro test work
permit, the checklist portion (before the test) shall be completed. This checklist shall be kept with the hydro test work
permit.

(Paragraph numbering coincides with Section 5 of this GI for ease of reference.)

5.1 BEFORE START OF TEST

 = Yes or satisfactory
X = No or not satisfactory
NA = Not Applicable

5.1.1 ASSIGN RESPONSIBILITY

_____ Proponent organization has assigned persons responsible for the test.
_____ For major tests, representatives from Inspection and the responsible proponent organization
shall monitor testing.
_____ Before any test(s) are carried out, the proponent organization shall inspect equipment, where
applicable.

5.1.2 ISSUE WRITTEN, APPROVED PROCEDURES

_____ Written, approved procedures are at the job site.

(Exceptions: Written procedures are not mandatory for certain tests, e.g., household utilities.)
_____ Procedures are approved by proper authority.
_____ All important information on test pressures (e.g., timing and duration at every pressure rise step)
are recorded.
_____ Procedures include minimum requirements as follows:
 Pressure test or hydrostatic test diagram
 Test manifold arrangement
 Location of blind flanges and isolation valves
 Location of check valves (flappers to be removed, if necessary)
 Location of lowest rated component that determines test pressure
 Location of air vents
 Relief valve size and set pressure
 Vacuum valve size and set pressure
 Test medium
 Test pressures
 Special support requirements
 Chemical additives
 Test sequence
 Minimum temperature allowed
 Inspection requirements
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 Areas to be kept free of people

 Location of barricades
 Location of warning signs and markings for test area
 Work permits required
 Test medium disposal method
 Additional or special personnel safety equipment required
 Safety Instruction sheets
 Emergency communication required and the methods
 Location of the filling point
 Listing of correct sequence and necessary torque of all blind flange bolts and a
requirement to verify proper torque when bolting
 Use of properly rated gaskets
 Verification of compliance with the manufacturer’s rating specifications (e.g., quality,
service use, pressure rating) for all gaskets used

5.1.3 USE PROPER TEST MEDIUM

_____ Is water the test medium?

_____ If not, is the use of a test medium other than water justified?
_____ If water is not the test medium, are precautions taken to prevent hazardous conditions?
_____ Personnel have personal protective equipment for protection against burning from hot water.

5.1.4 SELECT AND TREAT HYDROSTATIC TEST WATER

_____ SAES-A-007 Section 6.1 followed for selection and treatment of hydrostatic test water.

5.1.5 USE APPROPRIATE TEST EQUIPMENT

_____ Equipment includes minimum requirements as follows:

(Exceptions: Certain tests will not need all equipment listed, i.e. household utilities)
_____ Relief valve tested in accordance with SAEP 319, tagged “TEST” with set pressure and date.
_____ Relief valve has adequate capacity (consult with Consulting Services Department or Process &
Control Systems Department, if necessary).
_____ Relief valve has proper set pressure (consult with Consulting Services Department or Process &
Control Systems Department, if necessary).
_____ No isolation valve in relief valve's outlet.
_____ No isolation valve in relief valve's inlet. (Exception: Relief valve may be installed on existing
valve connection if removal of the valve is not practical because of liquid in the system, but the
valve must be sealed open during the test.)
_____ Relief valve located in system under test and near test pump or other test medium supply.
_____ Two or more accurate and reliable pressure gauges of proper range calibrated within 30 days of
the pressure test.
_____ Pressure gauges have isolation and bleed valves.
_____ Pressure gauges are in proper locations.
_____ Pressure gauges at the test pump or test medium supply can be read by the operator.
_____ Blowdown valve on test piping.
_____ Isolation valve on test piping.
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_____ Blowdown valve on system under test readily accessible and piped or drained to a designated
location, drain or area.
_____ Test piping pressure tested to at least 20 percent above test pressure of the system under test.
(Exception: Final connection between test manifold and system under test may be tested to
maximum system test pressure only if a higher test pressure is impractical.)

5.1.6 OBTAIN WORK PERMITS

_____ Necessary work permits obtained

_____ Cold work
_____ Hot work
_____ Confined space entry
_____ Equipment opening/Line break

5.1.7. ISOLATE EQUIPMENT NOT ADEQUATE FOR TEST PRESSURES

_____ Appurtenances that are not part of the test are isolated during the test.
_____ Provisions made to ensure that no overpressuring can occur in equipment that is not being
tested.

5.1.8 PREVENT OVERLOADS FROM WEIGHT OF LIQUID

_____ Will the weight of the test liquid overload the system?
_____ If so, are temporary supports or other means provided to prevent overload? Consult with
Consulting Services Department for appropriate stress calculations, if necessary.

5.1.9 HANDLE CHEMICALS SAFELY

_____ Personnel use protective equipment for handling chemicals according to the Safety Data Sheets
or Chemical Hazard Bulletins from the Environmental Protection Department’s website.

5.1.10 AVOID FAILURE BY BRITTLE FRACTURE

_____ Temperature of the test medium is above the temperature at which the impact requirements are
met by the material to avoid a brittle fracture, as per SAES-A-004, General Requirements for
Pressure Testing.

5.1.11 CONTROL ACCESS TO THE SITE

_____ In plant areas and shops, the test area shall be marked and warning signs are posted to alert
approaching personnel, where practical.
_____ Personnel are posted at the plant site to keep the test area clear of all people not connected with
the test, if necessary.
_____ For systems outside of plant areas, warning signs are placed at locations where people could be
exposed.
_____ For a pipeline crossing underneath a road, traffic is diverted or stopped during the test, or
personnel are posted.

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_____ For an above ground pipeline parallel to a road within 30 m (100 ft), traffic is diverted or
stopped during the test, or a waiver is granted. If this is not practical, the responsible area Loss
Prevention office should be contacted to confirm that the test can be conducted safely.

5.1.12 ADVISE SAUDI ARAMCO AFFAIRS OF NON-SAUDI ARAMCO EXPOSURES

_____ If non-Saudi Aramco facilities will be exposed in a pressure test of Saudi Aramco facilities,
Saudi Aramco Affairs will be notified.

5.1.13 NOTIFY INDUSTRIAL SECURITY OF TESTS REQUIRING TRAFFIC CONTROL

_____ Industrial Security is notified of tests requiring their involvement in controlling traffic at the test
site.

5.1.14 PUBLICIZE TESTS INTERFERING WITH TRAFFIC

_____ Tests that will interfere with traffic are publicized in the Saudi Aramco Highlights and Notices.
The time of the test should not occur during peak traffic hours, if possible.

5.2 DURING AND AFTER TEST

5.2.1 _____ Personnel shall wear the required personal protective equipment (PPE).

5.2.2 REMOVE AIR BEFORE PRESSURIZING (LIQUID TEST)

_____ High point vents open while system is filled at the low point.
_____ Vents are closed after air is removed from the system. (Exception: Pipelines having air
removed with scrapers are not vented and filled per the above.)

5.2.3 CONTROL PRESSURE RISE

_____ Pressure is increased gradually with at least 10-minute holds at each step in a strength test.
_____ Weaknesses are repaired and leaks are stopped before exceeding 50 percent of the strength test
pressure for tests using liquid or 173 kPa (25 psig)/50 percent of the strength test pressure,
whichever is the smaller, for any tests using air or other gas as the test medium.
_____ In strength tests using air or other gas, the pressure is increased in steps no greater than one-
tenth of the strength test pressure after reaching 50 percent of the test pressure.
_____ In strength tests using liquid, the pressure is increased in steps no greater than one-fifth of the
test pressure after reaching 50 percent of the test pressure.
_____ Weaknesses are repaired and leaks are stopped before proceeding to any higher pressure.

5.2.4 DEPRESSURIZE BEFORE STOPPING LEAKS OR REPAIRING

_____ Pressure is removed, except pressure due to head of liquid, before stopping leaks or repairing,
including tightening of bolts. (Exception: Bolts may be tightened in a tightness test if
specifically approved).

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5.2.5 RESTRICT APPROACH TO THE SYSTEM

_____ Vessels never previously tested or vessels with welds never previously tested are not to be
approached during the step-wise increase in pressure. The pressure at which the system under
test will be approached for close inspection shall be specified in the test procedure.
_____ Personnel carrying out the test shall be provided with a safe place from which the progress of
the test can be observed and controlled.
_____ Safety clearance distances shall be reviewed by the proponent organization for each individual
test, and safe clearance distances shall form part of the test procedure. Loss Prevention
Department and Inspection Department shall be consulted for advice, if necessary.
_____ Only personnel involved with the test shall be allowed near the system at any time during the
test.
_____ The test pump, if any, shall be located such that the pump operator will not be exposed to
danger in the event of a failure.

5.2.6 DEPRESSURIZE SAFELY

_____ Depressurizing valve and piping are arranged for safe discharge.
_____ System will not be depressurized by loosening bolts or unscrewing fittings.
_____ System is depressurized at a slow enough rate to prevent damage.
_____ Heat exchangers are monitored with pressure gauges if necessary to prevent excessive
differential pressures.

5.2.7 DISPOSE OF TEST MEDIUMS SAFELY

_____ Disposal procedures developed with the Environmental Protection Department and shown on
the approved test procedure are followed.

5.2.8 FOLLOW ADDITIONAL SAFETY PRECAUTIONS

_____ Temperature of the test medium is allowed to equalize with the environment to the extent
practical before pressurizing.
_____ The test pump is not left unattended during the test unless isolated with a valve.
_____ Temporary test piping is not allowed to remain pressurized unnecessarily.
_____ System is not allowed to remain unattended when filled with liquid unless a vent is open.
_____ Test relief valve is not removed until the test liquid has been drained.
_____ Test liquid is drained slowly with vents open to prevent a possible vacuum.

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