Rev: 03 Date :

05-30-2017

INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 PROCEDURE

5.0 DOCUMENTATION
1.0 PURPOSE

To define preparation and method used to conduct pressure testing of pipe as required in the
specification.

2.0 SCOPE

To ensure that the above ground piping system has been successfully tested according to the design limit
and specification.

3.0 REFERENCE DOCUMENTS

3.1 INTERNATIONAL CODES AND STANDARDS

ASME B 31.3

3.2 SAUDI ARAMCO DOCUMENTS

Saudi Aramco Engineering Standards

SAES-S-070 Installation of utility piping system

SAES – A – 004 General Requirement for Pressure Testing

SAES – A - 007 Hydrostatic Testing Fluids and Lay up Procedure

SAES – L –050 Construction Requirements of Metallic Plant Piping

SAES – L- 056 Pressure Testing of Plant Piping

SAES – B – 017 Fire Water System Design

04 – SAMSS-048 Valve Inspection and Testing Requirements

 SAEP –- 327 Disposal of wastewater from cleaning, flushing and hydrostatic
tests

G.I .2.100 Work permit system

G.I.2.102 Pressure Testing Safety
G.I .432 .000 Pipe line hydro test water disposal

G.I 447.003 Pressure relief valves, Routine tests and Inspections.

4.0 PROCEDURE

4.1 Responsibility

 The Hydro test Engineer shall be responsible for preparation of the test procedure, delivery of the
approved test package to job site and co - ordination with the inspection group and
implementation of the pressure test in a safe and timely manner.

 The Hydro test Engineer and QC Engineer shall be responsible in preparing all documents
pertaining to test packages.

 The Piping Engineer shall ensure the completeness of the piping system before testing through
pre-test punch listing

 QC Inspector to check the system, verify all QC documents and clears the system for Hydro
testing.

 The Asst. Piping Engineer and /or Hydro Testing Foremen shall prepare the system as per the
approved Hydro Test circuit Diagram.

 QC Inspector to check the system after the test pressure has been achieved and he shall request
that SAUDI ARAMCO to witness the hydro test.

4.2 SAFETY

 It is essential that safe practices are observed during hydro testing. All persons who work on the
test must be aware of the hazards and the necessary precautions to be observed for the duration of
test.
 The work area shall be cordoned off with a rope or warning tape and warning signs displayed.
Only persons directly involved with the pressure testing shall be permitted inside the area.
 Ensure no air has been trapped inside the pipe during filling operation. Relief valves and pressure
gauges shall be mounted in the upright position. The pressure gauge at the manifold shall be
visible to the pump operator.
 The piping system to be tested shall be properly supported and restrained from movements.

4.3 MATERIALS

 Hydro Test Manifold with test certificate

 Pressure gauges with valid calibration certificates
 Relief valve with valid calibration certificate
 Manual / Power operated hydraulic pump.
 All preparatory materials Test Blind, Spectacles, Temporary spools etc

4.4 GENERAL REQUIREMENTS

 Prior to the conduct of a pressure test, the pre-hydro punch lists shall be cleared. All piping
should be air blown thoroughly. After flushing, all strainers and filters shall be cleaned.
 Test fluid shall be injected at the lowest point and vented at the highest point in the system to
minimize risk of entrapping air.
 Temperature equilibrium must be attained between test fluid and piping system after filling and
before applying pressure.
 Pressure test gauges to be used should be calibrated as per SAES-A-004, Para.7.1.5.
 All piping systems while under test shall be protected from over pressure by relief valves that are
set 5% above test pressure of the line or system. The relief valve should be tested as per
SAES –A-004, Para 5.5.1.
 Hammering of the pipe while under pressure shall not be allowed in the process of examining
leakages.
 Test pressure shall be maintained for a minimum of 30 minutes or long enough to examine all
joints for leakage.
 Gaskets on all joints disturbed after pressure test shall not be reused. New gaskets shall be
provided.
4.5 SEQUENCE OF OPERATION

 All test manifolds shall be pre-tested separately from the system to at least 1.5 times the system
test pressure but not less than the pump discharge pressure (Ref. SAES-A- 004, Para.5.5.4).
Note: The Maximum allowable pressure or design pressure as given by Aramco is 75 PSI for
Sulfur Line, Hence as per ASME 31.3 for process piping the test pressure shall be 1.5 X Design
Pressure, i.e., 112.5 PSI.
The Maximum allowable pressure or design pressure as given by Aramco is 60 PSI for Steam
Line, Hence as per ASME 31.3 for process piping the test pressure shall be 1.5 X Design
Pressure, i.e., 90 PSI.
 The Relief Valve shall be calibrated to 118.25 PSI (for Sulfur line) & 94.5 PSI (for Steam Line)
i.e. 5% above the test pressure as per SAES-A-004. The pressure gauge range is from 0 to 300
PSI (30% to 80% range of the test pressure as per SAES-A-004)
 The material of pipe is ASME B36.10, ASTM A106 Grade B Class # 150.
 The system may be separated into sub-system for testing i.e., the hydro test shall be performed on
the spools.
 All pipes are aboveground hence they will be tested not less than 30 minutes to determine that
there are no leaks.
 We shall fill the pipe with approved test fluid (Utility Water) which shall be introduced at the
lowest point to the system. All vents shall be opened during filling and closed when entrained air
is removed.
 The system pressure will be raised slowly using Hand pump /power operated pump.
 At 50 percent of the strength test pressure, pressurization shall be stopped to check for leak.
 If any leakage is found the system shall be depressurized and then dewatered. Leaks shall be
repaired. Test fluid (Utility Water) shall be refilled and test will be continued.
 After satisfactory preliminary check for leaks at 50% of test pressure, the pressure shall be
increased in steps not greater than 10%of the strength test pressure with at least 10 minutes hold
at each steps to permit inspection for leakage (Reference: G.I.2.102. paragraph)
 If no leaks are discovered during these stages, pressurization shall be continued up to the
required test pressure. After reaching the test pressure the test system shall be isolated from the
pump.
 The test shall be considered satisfactory if there is no evidence of leakage or pressure loss after
the specified test period of 30 minutes or greater.
 Upon completion, the system shall be depressurized and the lines shall be drained fully keeping
all vents in the fully open position.
 The drained water will be disposed of safely into the sewer drains/ safer destinations, which are
acceptable to Saudi Aramco.
 The test result will be documented on the Piping Pressure Test Report.

Hydro-test Manifold Diagram

5.0 DOCUMENT:

 Piping Punch list

 System Flushing / cleanliness Record
 Re-instatement check List
 Pre-test checklist
 Post Test Checklist.