Pressure Testing Reference and Standards

Pressure Testing Reference Standards

Aramco QC Notes Level-8

Pressure Test Procedures
Hydrostatic Testing
Pneumatic Testing

✅ SAES-A-004 General Requirements for Pressure Testing

HYDROSTATIC TEST

A pressure test conducted using water or other approved liquid as the test medium.

PRE START-UP TEST

A pressure test to ensure tightness of flanged and threaded joints at the test Pressure. It is normally conducted before initial start-up, during commissioning or after T&Is.

PNEUMATIC TEST

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

PRESSURE TEST

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

REVALIDATION TEST

A pressure test performed to prove the integrity of existing piping or 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 with this standard and the applicable Code to verify the integrity of the piping systems or equipment for service at the design pressure.

SYTEM TEST

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

PRESSURE TEST PROCEDURE

Information assembled to ensure all requirements listed in GI-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 leaks in the system) at the test pressure.

✅ PRESSURE TESTING REFERENCE STANDARD

SATIP-A-004-02 Hydrostatic Testing of On-Plot Piping
SAES-A-004 General Requirements for Pressure Testing
SAES-A-007 Hydrostatic Testing Fluid & Lay-up Procedure
SAES-L-125 Safety Instruction Sheet for Piping & Pipeline
SAES-L-150 Pressure Testing of Plant Piping & Pipelines
G.I 0002.102 General Instruction Pressure Testing Safety

✅ HYDRO-TEST PACKAGE CONTENT

Test procedure SHALL be available at site all times;

Flow chart
Hydro test index
SIS / Test press diagram / legend
Piping plan drawing
P&ID drawing
Isometric drawing
Welding summary report including NDT report & RTFI assessment.
Support type & drawing
Valve test certificate
Flange joint inspection report
Internal cleaning & flushing report
Pre-test punch list – punch “A” should be close prior for proceeding test package review & testing.
Reinforcing pad pneumatic test report
Calibration report
Filling & pressurization report
Pressure test report
Lay-up report
Reinstatement
Final inspection report
Coating report

✅ ALL SYSTEM (PIPING & EQUIPMENT) WHILE PRESSURE TESTED SHALL BE PROTECTED FROM BEING OVERPRESSURED BY THE FOLLOWING:

RELIEF VALVE (s) of adequate capacity set to relieve at 5% above the test pressure 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. Sizing of these relief valves used for testing shall follow the requirements of API RP 520, Part 1. The relief valve(s) shall be tested, dated, and tagged within One Week prior to the pressure test for new construction projects, and within One
Month for maintenance operations.
In addition to the pressure relieving device, a bleed valve shall be provided to protect the piping and equipment from overpressure. The bleed valve shall be readily accessible in case immediate depressurization is required.
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.
PRESSURE GAUGES and pressure recorders shall be calibrated before the Test. The calibration interval shall not exceed one (1) month. Calibration certificates shall be made available to Inspection personnel prior to commencement of the pressure test. Stickers shall be applied indicating the latest calibration date.
All gauges shall have a range such that the test pressure is within 30 to 80% of the full range.
A minimum of two pressure gauges are required for the test system. One pressure gage shall be on the test manifold and the other(s) on the test system. Their accuracy shall be within 5% of one another.
When large systems are tested, Inspection personnel will determine the need for additional gauges.
Recording gauges shall be used where it is necessary to keep a permanent record, e.g., when the test duration exceeds four hours, or otherwise as required by this standard.
PRESSURE TESTING MANIFOLD in the actual system pressure test, it shall be separately pressure 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.