Saudi Aramco Engineering Standard
Engineering StandardSAES-A-00430 March 2005General Requirements for Pressure TestingDocument Responsibility: Inspection DepartmentSaudi Aramco DeskTop StandardsTable of Contents123456789Scope. 2Conflicts and Deviations. 2References. 2Definitions. 5General Requirements. 5Specific Testing Requirement. 8Test Preparation. 11Test Procedures. 13After Completion of Pressure Test. 14Appendix I - Sample Form of Request forNon-Destructive Testing In-Lieu ofHydrostatic Test. 16Appendix II - Sample of SA2642-ENGPressure Test Report Form. 17Previous Issue: 30 June 2003 Next Planned Update: 1 April 2009Revised paragraphs are indicated in the right marginPrimary contact: Patrick T. McGhee on 873-6486Page 1 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 20091SAES-A-004General Requirements for Pressure TestingScope1.1This standard defines mandatory general requirements governing in-situpressure testing of new and existing pipelines, plant piping and pressurecontaining process equipment (hereinafter called equipment). Specificrequirements are covered in the specific SAESs applicable to that equipment orpiping system. This standard supplements ASME B31's and other applicablecodes.1.2The requirements of this standard apply to field/shop fabricated piping systemsand field fabricated equipment.1.3This standard does not cover pressure testing of new, shop fabricated equipmentsuch as vessels, tanks, heat exchangers and skid mounted piping which arepurchased in accordance with the applicable SAMSS.Exception:Fin-fan coolers are to be tested in situ in accordance with paragraph 6.4.5.231.4This standard applies to pre start-up leak tests normally conducted byOperations during start-up, commissioning and T&I of the facilities inaccordance with approved plant operating procedures.1.5This standard does not apply to equipment as excluded in section 7.2.Conflicts and Deviations2.1Any conflicts between this standard and other applicable Saudi AramcoEngineering Standards (SAES's), Materials System Specifications (SAMSS's),Standard Drawings (SASD's), or industry standards, codes, and forms shall beresolved in writing by the Company or Buyer Representative through theManager, Inspection Department of Saudi Aramco, Dhahran.2.2Direct all requests to deviate from this standard in writing to the Company orBuyer Representative, who shall follow internal company procedure SAEP-302and forward such requests to the Manager, Inspection Department of SaudiAramco, Dhahran.ReferencesThe selection of material and equipment, and the design, construction, maintenance, andrepair of equipment and facilities required by this standard shall comply with the latestedition of the references listed below, unless otherwise noted.Page 2 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 20093.1SAES-A-004General Requirements for Pressure TestingSaudi Aramco ReferencesSaudi Aramco Engineering ProceduresSAEP-302Instructions for Obtaining a Waiver of aMandatory Saudi Aramco EngineeringRequirementSAEP-327Disposal of Wastewater from Cleaning, Flushing,and Dewatering Pipelines and VesselsSaudi Aramco Engineering StandardsSAES-A-005Safety Instruction SheetSAES-A-007Hydrostatic Testing Fluids and Lay-upProceduresSAES-B-017Fire Water SystemsSAES-D-008Inspection, Repairs, Alteration, Rerating andTesting of Existing Pressured EquipmentSAES-D-108Storage Tank Testing and InspectionSAES-H-101Saudi Aramco Paint and Coating SystemsSAES-K-001Heating, Ventilating and Air-ConditioningSAES-L-108Selection of ValvesSAES-L-150Pressure Testing of Plant Piping and PipelinesSAES-L-350Construction of Plant PipingSAES-J-901Instrument Air Supply SystemsSAES-S-020Industrial Drainage and SewersSAES-S-030Storm Water DrainageSAES-S-040Saudi Aramco Water SystemsSAES-S-060Saudi Aramco Plumbing CodeSAES-S-070Installation of Utility Piping SystemsSaudi Aramco Materials System Specifications01-SAMSS-010Fabricated Carbon Steel Piping04-SAMSS-048Valve Testing and Inspection Requirements32-SAMSS-004Manufacturing of Pressure Vessels32-SAMSS-005Manufacturing of Atmospheric TanksPage 3 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 2009SAES-A-004General Requirements for Pressure Testing32-SAMSS-006Manufacturing of Low Pressure Tanks32-SAMSS-021Manufacturing of Industrial Watertube Boilers32-SAMSS-029Manufacturing of Fired HeatersSaudi Aramco Form and Data SheetForm 2642-ENGPressure Test Report FormSaudi Aramco General InstructionsGI-0002.102Pressure Testing SafelyGI-1781.001Inspection, Testing and Maintenance of FireProtection EquipmentSaudi Aramco Bottled Gas Manual Section V3.2Industry Codes and StandardsAmerican Petroleum SocietyAPI RP 520Part I - Sizing, Selection, and Installation ofPressure Relieving Devices in RefineriesAmerican Society of Mechanical EngineersASME B31.1Power PipingASME B31.3Process PipingASME B31.4Pipeline Transportation Systems for LiquidHydrocarbons and Other LiquidsASME B31.5Refrigeration PipingASME B31.8Gas Transmission and Distribution PipingSystemsASME B31.9Building Services PipingASME SEC VArticle 10 Leak TestingASME SEC VIRecommended Rules for the Care and Operationof Heating BoilersASME SEC VIII D1 & 2 Boiler and Pressure Vessel CodeNational Board of Boiler and Pressure Vessel InspectorsNB 23National Board of Inspection CodePage 4 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 20094SAES-A-004General Requirements for Pressure TestingDefinitionsHydrostatic Test: A pressure test conducted using water or other approved liquid asthe test medium.Pre Start-up Leak Test: A pressure test to ensure tightness of flanged and threadedjoints at the test pressure. It is normally conducted before initial start-up, duringcommissioning or after T&Is.Pneumatic Test: A pressure test conducted using air or other approved gas as the testmedium or in conjunction with liquid.Pressure Test: A test conducted to piping or equipment by subjecting it to an internalpressure using liquid or gas to ensure strength or tightness of the system at the testpressure.Revalidation Test: A pressure test performed to prove the integrity of existing pipingor equipment. This test is administered by the proponent organization.Service Test: A pressure test conducted at operating pressure using the service fluid.Strength Test: A pressure test at an internal pressure determined in accordance withthis standard and the applicable Code to verify the integrity of the piping systems orequipment for service at the design pressure.System Test: An in-situ pressure test applied to a group of piping and equipment testedas a system.Pressure Test Procedure. Information assembled to ensure all requirements listed inGI-0002.102 , all referenced Saudi Aramco standards and Industrial standards are met.Tightness Test: A pressure test to ensure tightness of the piping system (i.e., no leaksin the system) at the test pressure.5General Requirements5.1General Instruction GI-0002.102 "Pressure Testing Safely" shall be followedduring pressure testing.5.2Pneumatic testing5.2.1Pneumatic testing is not permitted without written approval of theManager, Inspection Department, unless specifically allowed by thisstandard or the referenced Saudi Aramco SAESs or SAMSSs. This test,when conducted, shall be in accordance with GI-0002.102 for additionalsafety requirements.Page 5 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 20095.2.2SAES-A-004General Requirements for Pressure TestingPneumatic testing with air of piping systems or equipment which havebeen in flammable service shall be concurred by the Manager, LossPrevention Department.5.3The effect of the static head of the testing liquid shall be considered whendetermining the effective test pressure of any elements within a tested system.5.4Test pressures and test durations shall be based on the applicable Aramcostandards.5.5Protection from OverpressureAll systems (piping and equipment) while being pressure tested shall beprotected from being overpressured by the following:5.5.1 Relief valve(s) of adequate capacity set to relieve at 5% above the testpressure shall be installed unless the test pressure is less than 85%SMYS at which time it can be set at 10% above the test pressure. Sizingof these relief valves used for testing shall follow the requirements ofAPI RP 520, Part 1. The relief valve(s) shall be tested, dated, and taggedwithin one week prior to the pressure test for new construction projects,and within one month for maintenance operations.5.65.5.2In addition to the pressure relieving device, a bleed valve shall beprovided to protect the piping and equipment from overpressure. Thebleed valve shall be readily accessible in case immediatedepressurization is required.5.5.3An isolation valve shall be provided between the pressure testingmanifold and the system being tested. The isolation valve shall be ratedfor the manifold test pressure when in the closed position.5.5.4Before employing the pressure testing manifold in the actual systempressure test, it shall be separately pressure tested to at least 1.2 times thesystem test pressure but not less than the discharge pressure of the pumpused for the pressure testing.Pressure Test Procedure5.6.1 A pressure test procedure shall be prepared by the responsibleengineering group and made available to Inspection prior to conductingthe test. The test procedure shall be available on site at all times.The pressure test procedure shall include all required documentationspecified in GI-0002.102, paragraph 5.2.Page 6 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 2009SAES-A-004General Requirements for Pressure TestingDuring a pneumatic pressure test a leak test shall be performed inaccordance with ASME SEC V Article 10 and Article 10 Appendix Iexcept the pressure shall be 5 – 10 psi instead of the design pressure. Acalculation sheet indicating adequacy of the test Relief Valve shall beincluded in the procedure.5.6.2A request for NDT in lieu of pressure testing shall be submitted forapproval as permitted in the specific SAES listed in Section 6 below. Asample form is provided in Appendix I. This form or an equivalent shallbe processed prior to NDT.Commentary Note:The plant manager will sign the form for existing facilities and theInspection Department Manager will sign for new construction projects.5.7The requirement for pre start-up leak tests and service tests during initial start-upand T&Is shall be as follows:5.7.1 New systems after strength tests and prior to initial start-up:5.7.25.7.1.1For systems with maximum operating pressures greater than6.894 MPa (1000 psi), a leak test with inert gas, followed by aservice test, shall be conducted at the maximum operatingpressure of the piping system. Oil flowlines, trunklines,testlines and water injection lines are excluded from thisrequirement.5.7.1.2For systems with maximum operating pressures less than 6.894MPa (1000 psi), a pre start-up leak test with inert gas or steam(if designed for steam service) shall be conducted at theavailable inert gas or steam system pressure (not exceeding themaximum operating pressure), or pressure as recommended byresponsible Operation Engineering Unit, followed by a servicetest at normal operating pressure of the piping systems. Wheninert gas or steam are not available, the service test will satisfythe pre start-up leak test requirements.Existing systems after T&Is:5.7.2.1For systems with maximum operating pressures greater than6.894 MPa (1000 psi) which are in hydrogen service or in sourservice with hydrogen sulfide concentrations higher than 0.1mole %:Page 7 of 17
Document Responsibility: Inspection DepartmentIssue Date: 30 March 2005Next Planned Update: 1 April 2009SAES-A-004General Requirements for Pressure Testing5.7.2.1.1 A pre start-up leak test with inert gas shall beconducted after major T&Is. The test pressure shallbe determined by the plant Operating Department.For minor T&Is, the pre start-up leak test shall beconducted per 5.7.2.2.5.7.2.1.2 The pre start-up leak test shall be followed by aservice test at the normal operating pressure of thepiping.Commentary Note:A major T&I is defined as either a catalyst changeor a major disassembly of flanges, gaskets, etc.The local Operation Engineering Unit andInspection Unit have the responsibility to definewhen a T&I is considered as major. This definitionmust be made during the pre-T&I scope of work toallow Operations sufficient time to have inert gason-site prior to start-up of the facility.5.865.7.2.2For all other systems and pressures, a pre start-up leak test withinert gas or steam (if designed for steam service) shall beconducted at the available inert gas or steam system pressure(not exceeding the maximum operating pressure), or at pressureas recommended by responsible Operation Engineering Unit,followed by a service test at normal operating pressure of thepiping systems. When inert gas or steam are not available, theservice test will satisfy the pre start-up leak test requirements.5.7.2.3Procedures for both pre start-up leak tests and service tests shalladdress, to the extent possible, the safety precautions providedin GI-0002.102 "Pressure Testing Safely".If the drop in ambient temperature may cause the test medium to freeze duringthe test, appropriate precautionar
SAES-L-108 Selection of Valves SAES-L-150 Pressure Testing of Plant Piping and Pipelines SAES-L-350 Construction of Plant Piping SAES-J-901 Instrument Air Supply Systems SAES-S-020 Industrial Drainage and Sewers SAES-S-030 Storm Water Drainage SAES-S-040 Saudi Aramco Water Systems SAES-S-060 Saudi Aramco Plumbing Code .
May 19, 2014 · Aramco, Dhahran. 3 References 3.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement. 3.2 Industry Codes and Standards American National Standards Instit
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