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BERRI DEVELOPMENT

ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

HYDRO TEST PROCEDURE


FOR PIPELINE SYSTEM

PRABHU AYMAN ALKHWANKY ROY MATHEW

SUBMITTED BY REVIEWED BY APPROVED BY ACKNOWLEDGED BY


BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

TABLE OF CONTENTS

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITION
5.0 RESPONSIBILITY
6.0 TEST PROCEDURES
7.0 SAFETY PRECAUTIONS
8.0 APPENDICES
9.0 ATTACHMENTS

1.0 PURPOSE
It is the Purpose of this procedure to ensure the pressure retaining
properties of field fabricated piping and pipeline systems, which are
designed and constructed in accordance with ASME B31.3, ASME B31.4,
ASME B31.8 and relevant Saudi Aramco Standards listed in Section 3.

2.0 SCOPE
This Procedure defines the Pressure Testing requirement for all newly
constructed pipeline under this project “BERRI DEVELOPMENT ONSHORE
FLOWLINES & TIE INS PROJECT”.
CONTRACT NO: 6600044385 & BI JOB NO: BI-10-09561-001
3.0 REFERENCES
3.1 Saudi Aramco Engineering Standards:
SAES-A-004 - General Requirement for Lieu of Pressure Testing
SAES-A-007 - Hydrostatic Testing Fluids and Lay-up Procedures
SAES-L-310 - Design of Plant Piping
SAES-L-350 - Construction of Metallic Plant Piping`
SAES-L-150 - Pressure Testing of Plant Piping and Pipelines
SAES-L-410 - Design of Pipelines
SAES-L-450 - Construction of On-Land and Near-shore Pipelines
SAEP-327 - Disposal of wastewater from cleaning, flushing and hydrostatic
test
SAEP-1160 - Tracking and Reporting of Welding, NDT, and Pressure
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

Testing for Capital Project

3.2 Saudi Aramco General Instruction:


G.I.2.100 - Work Permit System
G.I.2.102 - Pressure Testing Safety
G.I.432.000 - Pipeline Hydro test Water Disposal
Safety Instruction Sheet (SIS) form SA 2821

3.3 American Society of Mechanical Engineers:


ASME B31.3 - Process piping
ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons
ASME B31.8 - Gas Transmission and Distribution Piping Systems

4.0 DEFINITION
Pressure Test: A test conducted to piping or equipment by subjecting it to an
internal pressure using liquid or gas to ensure strength or tightness of the
system at the test pressure.

Hydrostatic Test: A pressure test conducted using water or other approved


liquid.

Pneumatic Test: A pressure test conducted using air or other approved liquid
as the test medium or in conjunction with liquid.

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 to set standard and code to verify the integrity of the piping system
or equipment for service at the design pressure.

Tightness Test: A pressure test to ensure tightness of the piping system (no
leak in the system) at test pressure.

System Test: An in- situ pressure test applied to a group of piping and
equipment tested as a system.

Pre Start-up Leak Test: A pressure test to ensure tightness of flanged and
threaded joint at normal operating pressure. It is normally conducted before
initial start-up during commissioning.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

5.0 RESPONSIBILITY
5.1 The Managers for Engineering, Construction and QA/QC are
responsible for planning, preparing, collaborating, leading in implementing and
execution of this activity (Hydro testing) in a timely and safe manner.

5.2 Engineering is responsible for the preparation of Test Packages supported


by QA/QC in providing some of the documents that will be included in the
content of the Test Packages such as the Weld summary list, NDT reports,
Calibration and Test Certificates for pressure and temperature gauges, valves,
safety relief valve, test manifold, water analysis etc.

5.3 The Mechanical Engineer shall be responsible for reviewing the


Hydrostatic Test Package prior to forwarding Saudi Aramco for Punch
listing/Review as required.

5.4 The Construction Superintendent/Supervisor with their crew shall be


responsible for making all necessary preparation of the hydrostatic test
including cleaning and for performing the test in accordance with this procedure
and instruction.

5.5 The QC Inspector shall be responsible for preparing Hydrostatic Test


Record, which specify the detailed scope of work such as test pressure,
position of pressure gauges and testing fluid and identify equipment such as
vessels, pumps and instruments that are to be isolated from pipe work during
the Hydro test. He shall be responsible for the monitoring of the test, inspection
after full pressurization and recording the results.

5.6 Safety Supervisor is responsible for ensuring that all safety requirements
as per G.I.2.100/102 are being followed throughout the activity.

6.0 TEST PROCEDURE


6.1 Before Hydro test
a. Prior to the start of the test, the Construction Supervisor & QC Inspector shall
verify that all other activities (except pressure test) are completed, punch list
item A are cleared and equipment such as vessels, pumps and instruments are
isolated from piping by using blinds or other suitable means. New piping
systems shall be flushed clean of loose scale and debris or scraped prior to
commencement of pressure testing. In addition, pipe spools cleaning and
flushing shall be done.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

b. This verification shall be accomplished by reviewing the applicable steps of


the Saudi Aramco Test and Inspection (SATIP) and that all non-conformances
have been completed.

c. Test Packages shall be submitted to SAUDI ARAMCO for review before


commencing of Hydrostatic Test. The Hydrostatic test package shall include,
but not limited to the following:

Hydrostatic Test Procedure


Piping Plan Drawing
Hydro test Diagram marked in applicable Isometrics
P & ID with Test Limits
Isometric list and Isometrics (if applicable)
Safety Instruction Sheets (SIS)
Welding Report
Weld joints Summary Reports
NDT reports
Test Manifold Test Certificate
Test Instruments Calibration Certificates
Valve Testing Reports
Scraping/Pigging/Flushing Reports
Welding Inspection Log
Pre-Hydro test Check List
Flange / Gasket Check List
Punch List Report
Water test Analysis
Pre-test punch list
Test pack flow chart as per SAIC-A-2003 (attachment 2 -TEST PACKAGE
FLOW CHART)
Reinstatement procedure and checklist (SAIC-A-2003 attachment 1 section
8)
Hydro test Report Form
Hydrostatic test diagram which shows piping limits
Test manifold and equipment included in each test.

d. Testing Components
Hydro test manifold shall be tested for 1.2 times of the system test
pressure prior to conduct the test for the project. The Test Certificate shall be
available and valid during the execution of Hydro testing.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

The capacity & Location of hydrostatic pump shall be noted in such a way
that the Pressure Gauge reading is visible to the Pump Operator.
The range of pressure gauges i.e. the test pressure is within 30 % to 80%
of the full range. Minimum of two (2) on large systems Inspection will
determine the need for extra gauge. Gauges used for testing shall be
installed as close as possible to the low point (drain) and high point (vent)
of the piping system
Pressure Gauges, Pressure and Temperature Recorders calibration
interval shall not exceed one month prior the test date as per SAES-A-004
Para. 5.12.6.2.
Pressure gauge accuracy shall be within 5% of one another.
The pressure gauges to be used must have a calibration sticker indicating
the date of calibration and date of expiry. Calibration certificates shall be
available prior to commencement of the pressure test.
Setting of the Relief valve to relieve at 5% above the hydro test pressure.
The Relief valve shall be tested, dated, and tagged within two weeks prior to
the hydro test. In addition to the pressurerelieving 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 depressurization is
required in accordance with SAES-A-004, para. 5.7.2.
An isolation valve shall be provided between the pressure testing manifold
and the system being tested. The isolation valve shall be rated for the
manifold test pressure when in the closed position.(SAES-A-004 Para 5.7.3)
Before employing the pressure testing manifold in the actual system, it
shall be separately tested to at least 1.2 times the system test pressure but
not less than the discharge pressure of the pump used for the pressure
testing.(SAES-A-004 Appendix B ).
Pressure and Temperature recording gauges shall be used for all buried
piping systems on plot as per SAES-L-150 for pipelines.

e. All openings except test medium inlet and vent opening shall be closed using
correct rating plugs, caps or other suitable means. Field Fabricated Blinds shall
not be used without proper calculations for the thickness proof.

f. Support for hydrostatic test, if used, shall ensure a safe test. In order to
inspect all welded joints, no supports shall be placed on or over any weld joints
of the pipe work under Hydro test.

g. Following components shall be removed, replaced with temporary spool


piece or isolated from pipe work, according to the Hydro test package.
Orifice plate
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

Filter element
Temporary strainer
Safety and relief valve (Permanent)
Rupture disc
Expansion joint
In-line instruments (If piping have been flushed prior to testing, on/off valve
may be remained in line, but valve shall be kept open during test and
flushing.)
Pressure gauge (Permanent)
Temperature gauge and thermo well
Steam trap
Mixing nozzle and mixer
Check valve discs shall be removed and securely attached to the outside
of
check valve prior to pressure test.
Soft seated ball and plug valve (unless piping have been prior to testing)
Equipment that cannot be drained.

j. Hydro Test Water


The water shall not be used for Hydrostatic test if its pH is less than 6
and/or its sulfate reducing bacteria (SRB) counts shall be 1000 per ml or less
as per (SAES-A-007 Para. 4.2.3).
The water to be used for Hydro test or subsequent Lay- up shall be clean
and free from suspended matter. Suspended matter in the water shall be
extracted before use by a filter capable of removing 99% of all particles
53um (2.1 mil) in diameter and larger, or equivalent to using a 270 mesh
wire mesh screen. (SAES-A-007 Para 4.2.5)
Water that could result in harm to humans must not be used for Hydro
testing. For example, service water containing hydrogen sulfide levels that if
released to atmosphere would result in air concentrations of 10 ppm
hydrogen sulfide or greater in the immediate area of the hydro test must not
be used.(SAES-A-007 Para 4.2.6)
Prior to filling the system, lay-up will be determined. This determination will
be made based on the system, lay-up duration and the requirements of the
Proponent. All lay-up activities shall be performed per the requirements of
SAES-A-007 and will be recorded in relevant QC Form. The water described
above shall be used as a test medium unless otherwise specified for testing
of stainless steel. The water to be used for the testing of stainless steel shall
have maximum chlorine content of 50 ppm to be verified at the site before
injection into the system per SAES-A-007.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

6.2 During Hydro test


a. Filling the water
All vents and other connections that can serve, as vents shall be opened to
purge possible air pocket while the item is being filled with water. Fill from
lowest point to minimize trapped air.
Before applying pressure, the test operator shall check the test equipment
to assure that all low pressure filling lines and other appurtenances that
should not be subjected to the test pressure have been disconnected or
isolated by valves or other suitable means.
Thermal Stabilization – A thermal stabilization period will begin on
completion of filling. Duration will be approximately 4 hours for plant piping
and 24 hours for pipeline.

b. Application of Pressure
 The system may be separated into sub-system for testing. The Hydro test
circuit diagram shall show the limit and method of isolation for system or
sub-system shall be prepared prior to testing.
 Lines above ground shall be tested for a sufficient time, not less than 30
minutes to determine that there are no leaks. The strength test pressure
shall be maintained for two hours per SAES-L-150 para. 8.1.
 A 24 hour recorded tightness test shall be applied when the pipelines is
buried or insulated, or is partially buried or insulated for more than 300 m
(1000 ft) or 10% of its total length whichever is less.
 The system/sub-system will be filled with the approved test fluid
introduced from the lowest point of the test circuit. All vents shall be opened
during filling and closed when entrapped air has been vented.
 The approved Hydro test manifold will be connected to the line. The
system pressure will be raised slowly using hand pump/power operated
pump.
 At 50 percent of strength test pressure, pressurization shall be stopped to
check for leak.
 If any leakage is found, the system shall be depressurized and then
dewatered. Bolts will be loosed prior to repair. Test fluid 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 one-fifth of the strength
test pressure with at least 10 minutes hold at each step to permit inspection
for leakage (ref. G.I.2.102. Para.5.16).
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

 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.
 When the test pressure is stabilized all joints, flange connection and
welded joints for the pipeline or pipelines under test shall be visually
inspected.
 The test shall be considered satisfactory and accepted if there is no
evidence of leakage or pressure loss after the specified test period of 30
minutes or greater, as per SAES-L-150, para. 7.2.
 In case there is a failure during the Hydro Test due to leakage on pipes,
joints connections on flange, welding joints and fittings, the testing will be
stop and the pipe lines under test must be drained before any repair plan is
executed. Once the repair is completed and accepted the Hydro testing will
proceed from the first step of the testing procedure till it reach the stage
when the pressure is stabilized and all joints are visually check and
accepted. The test is considered satisfactory and accepted if there is no
leakage and pressure loss.
 Upon completion, the system shall be depressurized and the lines shall be
completely drained keeping all the vents in the fully open position. The line
shall be dried and lay-up performed (if required) per the requirements of
SAES-A-007.
 Application of primer ON WELD prior to hydro test is not acceptable per
SAES-L-150 Para. 7.3.
 Inspect the line/system to ensure that all fittings and appurtenances are
returned to their required positions as detailed in the P& IDs.
 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. The isolation valve downstream of the manifold shall be
opened after the pump is disconnected, as per SAES-A-004 Para
6.1.2

6.3 After Hydro test


a. Water Disposal
 After completion of the hydrostatic test, vents and drains shall be opened
to remove all the water in the pipeline system. Air may be used to force
evacuation. No heat shall be applied for drying.
 After pressure test, piping system shall be checked visually as follows:

Whether all lines are cleared of loose scale and debris by use of air or
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

water.
All open ends to be closed after drying procedure.
Apply lay-up procedure for lines, which shall be used as per SAES-A-
007.
The drained water shall be disposed off safely into the sewer drains /
safer destinations, which are acceptable to SAUDI ARAMCO. Furnish
and lay temporary evasion pipe to drain the hydrostatic test water.

b. Lay-up of pipe spools and pipeline


Equipment must be laid-up after hydro testing unless it can be ensured
that it will be returned to service within 30 days from the first introduction of
hydro test water to the system. Use one of the lay-up methods as per SAES-
A-007 para. 5.2 and SAES-A-007 para.7 for requirements for specific
systems Lay-up procedures for pipelines under the responsibility of Pipelines
Department shall be approved prior to hydro test by the General Supervisor,
Pipelines Technical Services Division (PTSD), and by the Manager of the
concerned area. Approval of lay-up procedures for other equipment shall be
the responsibility of the Saudi Aramco Engineering Superintendent or his
designate.
Dry Lay-up method.(SAES-A-007 Para 5.2.3)
After acceptance of the pressure test, the test water from the pipeline shall
be displaced and discharged to an approved disposal area. Remove all
water from the system. For facilities other than pipelines, drain the system
completely, sweep and mop as required to ensure that no visible traces of
water remain. For pipelines, dewatering shall be performed by scraping with
a three-or four cup Displacement scraper or better system such as a gelled
scraper. Scrapers shall be driven by nitrogen or sweet gas unless the use of
dry air has been pre-approved.
- The pipeline will be dried to the require dew point of -1deg C or less. This
dew point will be maintained before pressurizing the line with dry sweet gas
or dry nitrogen till the commissioning stage.

Ambient Lay-up method. (SAES-A-007 Para 5.2.5)


Ambient Lay-up will be used only if all of the following conditions apply as
per SAES-A-007 Para 5.2.5.1
a. Drains are available at all low points to ensure complete removal of
water.
b. Corrosion allowance has been provided.
c. Pitting can be tolerated
d. Particulate rust can be tolerated
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

Remove all water from the system. For facilities other than pipelines, drain
the system completely, sweep and mop as required to ensure that no
visible traces of water remain. For pipelines, dewatering shall be performed
by scraping with a three-or four cup displacement scraper (or better) unless
system limitations make this option impracticable as per SAES-A-007 Para
5.2.5. 2. After removal of all water, close the system to prevent the entry of
sand or rainwater as per SAES-A-007 Para 5.2.5.3. Install a vacuum
breaker unless it is demonstrated that the system will not collapse under
vacuum as per SAES-A-007 Para 5.2.5.2

c. Reinstatement
All temporary items installed for testing purposes (e.g., manifolds, valves,
blinds, spacers, supports) shall be removed after the test. Permanent items
that were removed shall be reinstalled. Items, such as instrument air tubing,
check valve discs which were disconnected before testing shall be
reconnected. Isolation valves closed for the test purposes and that are
required to be in the open position for process reasons shall be opened. If
the valve cavity has a drain, the cavity shall be drained, (SAES-A-004 Para
7.4).

7.0 SAFETY PRECAUTIONS


7.1 Assign Responsibility
In accordance with G.I. 2.102, RTCC’s Mechanical Engineer shall ensure the
Pressure Testing Procedure shall be routed to the assigned responsible
person/unit.
1. RTCC shall assign persons to be responsible for:
a. Preparation of the test procedures.
b. Delivery of the approved test procedures to job sites.
c. Safety aspects of the pressure test.
d. Coordination and implementation of the pressure test in a safe manner.
2. Saudi Aramco Loss Prevention and Procurement shall review & approve
Pressure Test Procedure and ensure that the procedures reflect proper
planning and safe execution of pressure test by observing the following:

7.2 Before Start of Test


Appropriate Job Safety Analysis shall be submitted for review and approval by
concerned Saudi Aramco Organization.
Hydro test procedure must be verified & approved by Saudi Aramco before
any test are carried out.
Certified work permit receiver will obtain a properly signed work permit from
Saudi Aramco Representative prior to start hydro test activity.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

Warning signs will be displayed at barrier off areas indicating that hydrostatic
test is in progress. Only authorized personnel are allowed to enter the hydro
test area.
Water shall be the pressure test medium for pipelines. Air shall not be
permitted as pressure test medium in hydrocarbon service unless the system
has been cleaned to avoid an explosive hydrocarbon-air mixture.
Oxygen, toxic gas, liquids above their flash points or atmospheric boiling
points, liquids above 66ºC (150ºF), except where necessary for pressure
testing hot tap connections on hot lines shall never be used as a pressure test
mediums because they are extremely hazardous.
Steam may be used as a pressure test medium only in tightness test (per
G.I.2.710) and service tests.
Personnel shall wear appropriate personal protective equipment to protect
against exposure to hot liquid when a liquid above 49ºC (120ºF) and below
66ºC (150ºF) is used as a test pressure medium, such as aquifer water in
testing water injection lines.
Hydrocarbon shall never be used as a pressure test medium for a system that
will be in oxygen service.
Chemical treatment and selection of hydrostatic test water per SAES-A007,
shall be followed to avoid corrosion and possible running failures from
hydrostatic test water.
Test equipments such as test manifolds, relief valves, pressure gauges,
pumps to be used shall be verified, tested, calibrated prior to start activity.
Appurtenances not part of the pressure test shall be blinded to exclude
equipment which cannot withstand the test pressure. If isolation valves are
used in lieu of blinds, provisions shall be made to ensure that no over
pressuring can occur in equipment that is not being tested, due to possible
valve leak.
Portions of the system such as supports, vessels, piping and foundations
shall not be overloaded by the weight of the test liquid.
Traffic shall be diverted or stopped when pipeline being tested crosses under
a road, a personnel shall be posted at the crossing to control traffic in the event
of an incident affecting traffic safety.
Saudi Aramco Representative will be informed on the details of the scheduled
hydrostatic testing if non-Saudi Aramco facilities will be exposed in a pressure
test.
RTCC will notify Industrial Security through SAPMT requiring Traffic Control
at the test site, such as tests of pipelines which cross roads. Test will not be
scheduled during peak traffic hours.
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

7.3 During and After Test


Air shall be removed from the system through vents at high points while the
system is filled at the low point. Air removal can be achieved by using scrapers
to displace air with liquid if pipeline is equipped with scrapping facilities.
Pressure rise during pressure test shall be gradual and under control to allow
time for material to strain, and time for personnel to check for leaks.
- Strength tests using a liquid test medium: 50% of the strength test pressure.
- Any tests using air or other gas as a test medium: 173 kpa (25 psig) or 50% of
the strength test pressure, whichever is lower value.
- Units: 1 Bar = 100,000 N/m² = 100kPa = 14.5 psi
Do not proceed to a higher pressure until weaknesses have been repaired
and leaks have been stopped.
System shall be depressurized (except pressure due to a head of liquid)
before any work is done to stop leaks or repair weaknesses, including
tightening of bolts.
Personnel carrying out the test shall be provided with a safe place from which
the progress of the test can be observed and controlled. Only personnel directly
involved with the test shall be allowed near the system when permitted.
Test pump shall be located such that the pump operator will not be exposed
to danger in the event of a failure.
Upon completion of the test the system shall be emptied in such a way as not
to cause vacuum and collapse. Depressurizing valve and piping shall be
arranged for safe discharge of the test medium. Loosening of bolts in a flange
or unscrewing fittings shall not be allowed as this might lead to injury.
Disposal of test mediums containing chemical additives must be approved by
the concerned Saudi Aramco units.
All temporary items installed for testing purposes (e.g., manifolds, valves,
blinds, spacers, supports) shall be removed after the test. Permanent items that
were removed shall be reinstalled. Items, such as instrument air tubing, check
valve discs which were disconnected before testing shall be reconnected.
Isolation valves closed for the test purposes and that are required to be in the
open position for process reasons shall be opened. If the valve cavity has a
drain, the cavity shall be drained, (SAES-A-004 Para 7.4).

8.0 APPENDICES:
8.1 Saudi Aramco Test and Inspection Plan (SATIP)
SATIP-A-004-02 - Pressure Testing-Hydrostatic Test of Plant Piping
SATIP-A-004-03 - Pressure Testing-Hydrostatic Test of Pipelines
SATIP-A-004-05 - Leak testing (Per SAES-A-004)
BERRI DEVELOPMENT
ONSHORE FLOWLINES & TIE INS PROJECT

DOCUMENT NAME: Document #


HYDRO TEST PROCEDURE NBC/RTCC/BERRI/QC/2020/0010

PROJECT NAME: DATE OF ISSUE: 12-JAN-2021


SOUTH BERRI WELL SITE FACILITIES
CONTRACT NO: 6600044385
REVISION NO: 00
BI JOB NO: BI-10-09561-001

8.2 Saudi Aramco Inspection checklist (SAIC)


SAIC-A-2001 - Review of Pressure Testing Procedure (Attached)
SAIC-A-2003 - Review of Test Package Preparation
SAIC-A-2005 - Review of Leak Testing Procedure
SAIC-A-2007 - Review of Procedure for Lay-Up of piping or Vessels
SAIC-A-2008 - Verification of Test Medium for Hydrostatic Testing
SAIC-A-2009 - Verification of Test Preparation and Test equipment for
Pressure Testing
SAIC-A-2010 - Pre-Test Punch Listing of On-Plot Piping
SAIC-A-2013 - Inspection of Filling & Pressurization for hydro testing of Piping
Systems
SAIC-A-2015 - Visual Inspection of Pressure Test
SAIC-A-2016 - Visual Inspection of Pneumatic Test for Reinforcing Pads,
Sleeves or Weld-Plus-Ends coupling
SAIC-A-2017 - Depressurization & disposal of Hydro test water
SAIC-A-2018 - Lay-up Inspection for piping & vessels
SAIC-A-2023 - Pressurization for Leak Testing
SAIC-A-2024 - Inspection of Leaks for tightness Testing
SAIC-L-2001 - Review of Internal Cleaning Procedure for Plant piping, line and
equipment
SAIC-L-2017 - Piping/equipment Internal Cleaning Inspection
SAIC-L-2139 - Pre-test Punch Listing of Cross country pipeline

8.3 Saudi Aramco Test Report (SATR)


SATR-A-2001 - Pressure/Leak Test Report
SATR-A-2002 - Calibration Test Report – Pressure Gauge
SATR-A-2003 - Calibration Test Report – Temperature Gauge
SATR-A-2004 - Calibration Test Report – Pressure Recorder
SATR-A-2005 - Calibration Test Report – Temperature Recorder
SATR-A-2006 - Calibration Test Report – Test Relief valve
SATR-A-2007 - Pre-Test Punch List Form
SATR-A-2008 - Piping/equipment Internal Cleaning Inspection
SATR-A-2009 - System Lay-Up Verification Report and Certificate
SATR-A-2010 - Pressure Leak Test Report
SATR-A-2011 - Re-Instatement Check List (Form)
SATR-A-2014 - Water Chemistry Report
SATR-A-6133 - Exception Item List (Not attached)

Saudi Aramco 2642-Eng. - Pressure Test Report Form

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