Procedure Welding Part 2

NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO.
LTD
RAS TANURA REFINERY CLEAN FUELS PROJECT
CONTRACT No.: 10100-25330
VALVE TESTING PROCEDURE
TABLE OF CONTENT.
SL. # DESCRIPTION PAGE #
1. PURPOSE 03
2. SCOPE 03
3. REFERENCE 03
4. DEFINITIONS 03
5. RESPONSIBILITIES 04
6. GENERAL REQUIREMENTS 05
7. TEST EXECUTION 06
8. INSPECTION 08
9. TEST REPORTS 11
10. SAFETY 11
11. PROTECTION AND STORAGE 12
12. HANDLING AND TRANSPORTATION 13
13. TRACEABILITY 13
14. ATTACHMENT 14
ADW-TR-RTCF-QP-ME-005, Rev.0 Page 2 of 14

NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD
1. PURPOSE.
To ensure that at COMPANY approved field pressure testing facility, all new valves designated for
isolation services (as specified by proponent are free from any leaks when subjected to a high
pressure hydrostatic seat test, before installation of the valves in the line and verified / inspected to
satisfy the customer in accordance with the current codes and standards, as required by the
COMPANY.
The valve testing which will be carried out at the COMPANY approved field pressure testing facility
shall be considered to be sufficient to accomplish the on field valve testing requirement as per SAES-
L-108 and shall be in accordance with the requirements of the applicable international codes and
COMPANY standards.
2. SCOPE.
This procedure states the minimum requirements to be followed for field valve testing activities as
prescribed in SAES-L-108, but done at the COMPANY approved field testing facility.
3. REFERENCE.
SAES-L-108 Selection of Valves

SAES-A-004 Pressure Testing
SAES-L-150 Pressure testing of plant piping and pipelines
SAES-A-007 Hydrostatic testing fluids & lay-up procedures
SAEP-035 Valve handling, Hauling, Receipt test & storage
04-SAMSS-035 General requirements for valves
04-SAMSS-048 Valve inspection and testing requirements
API 598 Valve inspections and testing
ANSI-B16.34 Valves, Flanged and Butt welding End
ASME B31.1 Power Piping
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation systems liquid Hydrocarbon and
other liquids
ASME B31.8 Gas transmission and distribution piping system
API SPEC 6D Specification for pipeline valves
G.1.2.102 Safety precaution for pressure testing
SAES-A-005 Safety instruction sheet
SAIC-L-2042 Field hydrostatic testing of isolation valves
SATIP-L-108-1 Valve inspection, Testing and installation
4. DEFINITIONS.
PROJECT : Ras Tanura Refinery Clean Fuels Project.
Company : Saudi Aramco.

Contractor : Tecnicas Reunidas.

Sub Contactor : Nawaf Mattar Al-Adwani cont. co. Ltd.
SAPMT : Saudi Aramco Project Management Team.
ASME : American Society of mechanical Engineers.
SAES : Saudi Aramco Engineering Standards.
SAEP : Saudi Aramco Engineering Procedure.
SAIC : Saudi Aramco Inspection Check List.
SATIP : Saudi Aramco Typical Inspection plan.
SATR : Saudi Aramco Test Report.

RFI : Request for Inspection.
QCP : Quality Control Procedure.
QC : Quality Control.
5. RESPONSIBILITIES.
5.1 Project Manager shall be responsible for the overall implementation of the company safety &
quality plan and ensure efficient execution of work in accordance with project specification and
this procedure.
5.2. QC Manager shall be responsible for ensuring all activities are carried out as per the project
quality plan, project specifications, and the approved quality control procedures. Ensure that the
field pressure testing of valves carried out as per project requirements and applicable Saudi
Aramco standards.
5.3. Construction Manager Responsible for all mechanical activities pertaining to this procedure
and to ensure Safe working practices are followed without exception
5.4. Qc Supervisor (Piping) coordinate the inspection activities and verify all the inspection reports,
SAIC, SATR and sign the documents. Assign qualified QC inspector for this task.
5.6. QC Inspector is responsible for inspection in accordance with specifications and procedures of
valve testing. Shall monitor the testing and if within the acceptance criteria, he should make a
port of accept/reject for the valve being tested. Shall have retention of QC reports records.

5.7. Document Controller responsible for to issue, maintain and controlling all documents required
for Valve Testing.
6. GENERAL REQUIREMENTS
 Before commencing testing, it shall be ensured that valve receiving inspection should have been
complete and all valve are received with a unique identification number marked/stenciled/tagged
on the valve.
 All valve 2” and large shall be tested in accordance with SAES-L-108. Butt and socket weld end
valve in normal pipe size 2” and smaller are exempt from the above field testing requirements
as per SAES-L-108.
 Valve testing pump shall be verified prior to start the valve testing activities. Testing medium
shall be water, complying with SAES-A-007.
 Calibrated pressure gauges used for test shall be calibrated by Saudi Aramco approved
Calibration agency with maximum one (1) month validity. All gauges should have a range such
that the test pressure is within 30% to 80% of the full range of the gauge. The accuracy between
two gauges shall be within 5% of one to another when used.
 An isolation valve shall be provide between the pressure testing manifold and system being
tested. The isolation valve shall be rated for the manifold test pressure when in the closed
position.
 All pressure testing manifold shall be separately pressure tested at least 1.2 times the system
test pressure but not less than the discharge pressure of the pump used for pressure testing.
 All blind flanges shall be standard blind flanges as per code.
 Test manifold shall have 100% NDT of all butt welds. Test manifold new construction shall be
revalidated for each new project and every 6 months for operating facilities.
 All gaskets used in the pressure test shall confirm to the specifications per SAES-L-109.
 Temporary blinds and gasket shall be of the same size and rating with the flange of the valve to
be tested.
 All required equipment and instruments for the Hydro test such as Hydro test pump, pressure
gauge, and relief valves shall be inspected prior to Hydro test.
 Relief Valve should be calibrated and set by a Saudi Aramco approved calibration agency within
a maximum of 1-week validity. Pressure test 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.
 Relief Valve testing within 1 week and pressure gauge Calibration within 1 month shall be

adhered to for all hydro testing activities. Calibration certificates shall be made available to the
“PROJECT INSPECTION” prior to each test.
 Test procedures, pressures, duration, leakage rate acceptance criteria shall be equal to those
against which the valves were originally purchased to Guidance may be obtained from the
manufacturer Test Certificates.
 All resilient (soft) seated isolation valves shall have zero leakage.
 Test procedures, pressure, duration and leakage acceptance criteria shall be equal to those
standards against which the valve were original purchased as per the Valve Datasheet. For all
resilient (soft) seated valves, it shall have zero leakage. For minimum test duration refer to API
598 Table 4/SAES-L-108 Para 4.7.5.
 The Test Water Sample shall be tested well in advance to verify the usability of the sources.
 Testing media shall be water complying with SAES A-007. Testing interval established for the
test water shall be weekly. Test water quality shall have a sulphate reducing bacteria (S.R.B)
count of 10³ per ml or less as determined by Rapid Check II method. Water chemistry report is
available at site during hydro test.
 For testing of stainless steel valves Water with chloride content shall not exceeding 50 part per
million shall be used and Ph. value 10 to 11. Water used for the hydro-testing of carbon steel
(P1) valves shall be clean and free from suspended matter that could lodge in the valve internals.
 For testing of Carbon steel valves water with chloride content shall not exceeding 250 part per
million shall be used and Ph. value 6 to 8.
 Test fluid temperature specified in the purchase requisition, the test fluid temperature shall be
within the range 5°C (41°F) to 50°C (122°F).
7. TEST EXECUTION.
 A jobsite meeting shall be held to review the test procedure and safety requirements for the
hydrostatic test.
 All material specification of the valve shall be checked to ensure compliance with the design
package and to verify the pressure rating meet or do not exceed the specified test pressure.
 Equipment’s used in the test shall be checked to ensure that the pressure rating are consistent
with the test requirements.
 One blind flange connected to the test manifold shall be installed to one side of the valve to be
tested and other fitted with a pressure gauge and bleed valve shall be installed to the other end
of the valve to protect the valve from over pressure in addition to the pressure relief valve and
shall be readily accessible in the event immediate depressurization required.
 Prior to water filling the valve shall be cleaned to ensure that ,it is clean and free from sand, dirt,

other construction debris and any foreign material behind the seat rings. Seat rings carries shall
be tapped lightly to loosen any lodged foreign material prior to cleaning. Valve shall then by
cycled opened and closed for a minimum of four time prior to commencement.
 If agreed by SAPID, compressed air may be used to clean inside surface of the valve prior to
blinding, filling and testing.
 After cleaning and fixing of blind the body shall be filled with clean water and air will be allowed
to escape through vents on the valve or the blind flanges, the water shall be allowed to stabilize
for a period not less than 10 minutes, the vents shall remain open during water filling.
 When the valve is full of water, allow the water to flow out for some time so that any remaining
trapped air is completely released and then the vent shall be closed.
 If required, the shell/Body test shall be perform by applying the pressure inside the valve with
the valve and closed. Test shall be performed by applying the appropriate pressure inside the
assembled valve with partially open, and any packing gland tight enough to maintain the test
pressure. Nonadjustable shaft seals (O rings, single rings and the like) shall not leak during the
body test.
 The seat pressure test shall be performed by applying the pressure inside the assembled valve
with the valve fully closed and the packing gland loose.
 A low pressure pneumatic seat at 35 kpa (5 psig) shall be substituted for the high pressure
hydrostatic seat test for flare system valves.
 Start pressurization at 50 % of the test pressure, stop pressurization and check for leak. If no
leaks are found continues pressurization at an increment of 20% up to the test pressure.
 The timing of the pressure holding period shall not start until the test pressure has been reached,
the valve under pressure with the pressure monitoring gauges has been isolated from the
pressure source and the external surface of the body member has been thoroughly dried.
 All valves shall be seat tested from both sides, with one side if the valve kept open for visual
inspection and leakage rate assessment at the test pressure. For a valve design to close against
pressure from one direction only and so marked, the pressure shall be applied on the pressure
side of the valve only.
 The pressure shall be applied successively to each side of the closed valve with the other side
open. Open to the atmosphere to check for leakage at the atmospheric side of the closure.
 The pressure shall be reduced to zero between all holding periods.

8. INSPECTION
 All inspections shall be conducted as per applicable SATIP-L-108-01.
 Valve that failed during test shall be tagged and mark and put in quarantine area until final
disposition, after that it will be sent to valve repair shop.
 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.
 After preliminary checks for leaks at the above pressures, the pressure shall be increased in
steps with at least 10 minute hold at each step to permit inspection for leaks and weaknesses.
The test pressure shall be in accordance with the below table taken from (API 6D primarily based
upon Flange Ratings).
VALVE BODY SEAT/CLOSURE

RATING / CLASS TEST (PSIG) TEST(PSIG)
ANSI 150 450 315
ANSI 300 1125 815
ANSI 400 1500 1085
ANSI 600 2225 1650
ANSI 900 3350 2440
ANSI 1500 5575 4075
ANSI 3000 9275 6785

SHELL TEST PRESSURE (API 598 TABLE 2)
SHELL TEST PRESSURE (MINIMUM)

VALVE POUNDS PER
CLASS
TYPE BAR GAUGE SQUARE INCH
GAUGE(PSIG)
150 26 400
Ductile Iron
300 66 975
Cast Iron
DN 50 to 300 (NPS 2 to 12) 125 25 350
DN 350 to 1200 (NPS 14 to 48) 19 265
Steel
Flanged 150 to 2500 b b
But Weld 150 to 4500 b b
800 c c
Threaded and socket weld
150 to 4500 b b
a. ASME B16.34 limits threaded and valve to class 2500 and lower.
b. Per ASME B16.34.
c. For class 800 valves, the shell test pressure shall be 1 ½ times the pressure rating at 38 oC (100 oF),
rounded off to the next higher (bar 25 psig), (see table 2 of API 602)


The maximum allowable leakage rate FOR SEAT TESTING shall be as specified on the below
attached table (API 598 table 5) rates are specified in drops per minute (16 drop = 1 milliliter).
Resilient seated Metal seated

Valve size All other valve
valve check valve
2” and below 0 (a) 0
2.5” to 6” 0 (a) 12
8” to 12 0 (a) 20
Above 12” 0 (a) 28
Note: (a) maximum allowable leakage is 3 cubic centimeters per inch nominal pipe size per
minute.
Note: (b) for all resilient (soft) seated valves, it shall have zero leakage.
 Where valve have double position effect function seat testing of these valves shall be
strictly conducted in accordance with manufacturer’s recommendations and
procedures.
9. TEST REPORTS
Test Records shall be made for each test by entries on Pressure Test Report Form ADW-QC-260 and
the applicable “Safety Instruction Sheet” per SAES-A-005. Pressure test reports shall also be duly
prepared in SATR-A-2001 formats. A detailed List or tracker shall be prepared which include the unique
valve number and the status of test results indicating passed and failed valves and submitted for
signature to ARAMCO representative after every test. The valves shall be tagged as passed or failed.
10. SAFETY PRECAUTION
 Valve testing facility needs to be approved by company prior to use. Safety Precautions for
pressure testing shall be followed during testing.
 Test crews & inspection personnel are trained to properly follow testing procedures to eliminated
water after testing and apply preservation measures such as manufacturing approved lubricants

& other corrosion control measures.

 Secure work permit prior to commencement of the test. Restriction notice and barricade shall be
provided around the system subject to test.
 Warning Signs “DANGER HYDROTEST IN PROGRESS” in English shall be placed at strategic
locations. Only Authorized personnel shall be allowed access to test vicinity.
 Hydro test Personnel must be informed of the potential hazard and the Necessary Precaution
required. No work shall be allowed on or near the system. If possible provide additional support
and anchor to carry the load in the system to anticipate Test Blind Distortion and thrusts due to
high pressure.
 Bleed Valve and Drain valve shall be readily accessible to the person doing the pressurization.
 Since the pressure test is higher than normal operating conditions, safety precautions must be
taken. Strictly no personnel other than the testing crew shall be allowed near the valves being
tested while the hydro test is in-progress. The inspectors/testing crew shall be located at a safe
distance, away from the valves being tested, while building-up the pressure.
 Close visual inspection for leakage during the test shall be made with safe precaution.
 No attempt shall be allowed to fix any leakages in the system while under pressure. Depressurize
the system to zero before doing any work or adjustment.
11. PROTECTION AND STORAGE

 New valves shall be stored with their packaging unopened, or if inspected shall be restored
accordingly. The store area should provide suitable means of protection against severe weather
conditions such as sand encroachment, rain, and other conditions that can affect valve integrity.
Valves should be supported off the ground.
 Any storage for a period of three months and longer shall be considered as long term storage.
At least once every 3 months, the valves shall be visually inspected to check the integrity of the
covers, caps, grease and other visible conditions.
 Prior to installation, long term stored valves shall be re-tested.
 On completion of the pressure test, all valves shall be drained completely. The test blinds shall
be opened and the internal parts cleaned to remove any foreign materials. Valves shall then be
carefully stroked, allowed time for water to descend from bonnets and thereafter completely
dried by blowing with dry compressed air.
 Gate valve shall have the internal surface of the seating groove coated in heavy grease
 A routine preservation check shall be performed to assure effective corrosion control measures
when valves are meant to be stored longer than 30 days after testing.

12. HANDLING HAS TRANSPORTATION
 In all cases valves shall be lifted using a suitably rated crane or lifting device that is capable of
handling the weight of the valve including any lifting accessories to be used such as beam etc.
 During lifting competent operators and riggers shall be utilized in order to ensure safe operation
are conducted.
 Valve shall when possible only be lifted by their specifically fixed attachments (lifting dyes).
 Critical points of the valve such as the valve end ports and stem shall be protected.
 Valve 24” and smaller shall be securely fixed to pallets prior to loading onto trucks.
 Valve larger than 24” shall be loaded onto trucks and shall be placed upon wooden skids no
greater than 100 mm thick. Skids shall be placed and spaced in order to ensure valve is safe
and stable during its journey to site.
 Valve shall be secured on trailers /trucks by means of ratchet locking webbing straps where
possible to avoid any damage to valve parts or coating.
 Should the need arise to use chains to secure valve on trucks or trailers then adequate soft
padding protection shall be placed in such a way that valve elements or coating is not damaged
in transit.
 When possible and to avoid unnecessary handling valves shall be transported directly to
installation location avoiding additional unloading and loading.
13. TRACEABILITY
 The traceability and identification system of pressure tested valves can be in accordance with
contractor/ subcontractor control system which is equivalent and acceptable to company.

14. ATTACHMENTS
 SATR-A-2001V

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NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO.

SL. # DESCRIPTION PAGE #

11. PROTECTION AND STORAGE 12

12. HANDLING AND TRANSPORTATION 13

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 2 of 14

SAES-L-108 Selection of Valves

Company : Saudi Aramco.

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 3 of 14

Contractor : Tecnicas Reunidas.

SATR : Saudi Aramco Test Report.

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 4 of 14

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 5 of 14

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 6 of 14

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 7 of 14

VALVE BODY SEAT/CLOSURE

ANSI 150 450 315

ANSI 300 1125 815

ANSI 400 1500 1085

ANSI 600 2225 1650

ANSI 900 3350 2440

ANSI 1500 5575 4075

ANSI 3000 9275 6785

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 8 of 14

SHELL TEST PRESSURE (API 598 TABLE 2)

SHELL TEST PRESSURE (MINIMUM)

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 9 of 14

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 10 of 14

Resilient seated Metal seated

10. SAFETY PRECAUTION

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 11 of 14

& other corrosion control measures.

11. PROTECTION AND STORAGE

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 12 of 14

12. HANDLING HAS TRANSPORTATION

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 13 of 14

ADW-TR-RTCF-QP-ME-005, Rev.0 Page 14 of 14

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