PTT_ Hydro Static Pressure Testing of Piping

8/6/2019 PTT_ Hydro Static Pressure Testing of Piping

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PREPAREDBY

NAPTT PUBLIC COMPANY LIMITED

CHECKED

BY ONSHORE COMPRESSOR STATION 4

PROJECT

APPROVED

BY

CERTIFIED

(PTT)NA

REV.

NO.

DATE REVISED

BY

APPROVED

BY

DESCRIPTION

D1 18-Feb-08 ISSUED FOR ITB

D2 11-Jun-08 ISSUED FOR ITB

SPECIFICATION FOR

HYDROSTATIC PRESSURE TESTING OF PIPING

SPC-0804.02-96.58 REV.D2

TOTAL 23 PAGES

AREA CODE OF SITE LOCATION

GENERAL AREA: 010

.

PTT PLC. CONTRACT NO. PTT PLC. PROJECT NO.

0804.02


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PTT PUBLIC COMPANY LIMITED

ENGINEERING SPECIFICATION

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CONTENTS

SECTION

1. GENERAL ............................................................................................... 3

2. PRESSURE TEST SYSTEM........................................................................ 4

3. TEST WATER CRITERIA........................................................................... 6

4. TESTING ................................................................................................ 7

5. BLINDS FOR PRESSURE TEST .................................................................. 8

6. TEST PACK PREPARATION ...................................................................... 8

7. FIELD PIPE TESTING PROCEDURES..........................................................10

8. TESTING PREPARATIONS .......................................................................12

9. HYDROSTATIC TEST PROCEDURE...........................................................14

10. SAFETY ................................................................................................15

11. SENSITIVE LEAK TEST ...........................................................................16

12. ALTERNATIVE TESTS .............................................................................16

13. VESSELS AND EQUIPMENT.....................................................................17

14. INSTRUMENTS ......................................................................................17

15. CLEANING .............................................................................................18

16. REPORTS AND RECORDS .......................................................................18

17. TEST RECORDS .....................................................................................18

APPENDIX I MINIMUM THICKNESS OF BLANK FOR PRESSURE TEST.............20

APPENDIX II. DETAILS OF TEST FACILITIES ....................................................22

APPENDIX III. TEST LIMITS SYMBOL..............................................................23


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1.0 GENERAL

1.1 Purpose

This Specification specifies pressure and leak test procedure and acceptance

criteria of piping works to perform minimum quality level.

1.2 Scope of Application

This specification covers all the projects which to be done by CONTRACTOR

(here in after refer to CONTRACTOR) in piping construction works.

1.3 Definitions

1.3.1 Category D Fluid Service (per ASME B31.3) - A fluid service in which all the

following apply:

(1) The fluid handled is nonflammable, nontoxic, and not damaging to

human tissues

(2) The design gauge pressure does not exceed 10.35 bar

(3) The design temperature is between -29 C and 186 C.

1.3.2 Category M Fluid Service (per ASME B31.3) - A toxic fluid service in whichexposure to very small quantities of the fluid in the environment can produce

serious irreversible harm to persons on breathing or bodily contact, even when

prompt restorative measures are taken.

1.3.3 Damaging to Human Tissues (per ASME B31.3) - A fluid which, under

expected operating conditions, can harm skin, eyes, or exposed mucous

membranes so that irreversible damage may be done unless prompt restorative

measures are taken. (Restorative measures may include flushing with water,

administration of antidotes, medication, etc.)

1.3.4 Calculated Test Pressure:- The test pressure determined in accordance with

paragraph 4.0

1.3.5 Minimum Test Pressure - The lowest allowable test pressure gauge reading.

(the calculated test pressure plus the additional pressure resulting from the

static head of the test fluid)

1.3.6 Maximum Test Pressure - The highest allowable test pressure gauge reading.

(the pressure test rating of the "weakest" component in the test system)


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1.4 References

1.4.1 Related Code and Standards

Piping construction works shall be performed in accordance with ASME B31.3

and ASME section IX.

(1) ASME B31.3 Process Piping

(2) ASME SECTION.IX "Welding and Brazing Qualifications"

1.4.2 Related Specifications

Following specification shall be used as a supplementary of this specification.

(1) Piping Construction (SPC-0804.02-96.51)

(2) Internal Cleaning of Piping (SES-PR. Q2- 99-0204.10-3500-013)

1.5 Units

Unless otherwise specified, metric, Celsius and Kilogram units sell be applied

as the measurement system for the drawings and document to be submitted.

However, nominal sizes of piping component shall be in accordance with inch

system, which abbreviation in (B)

2.0 PRESSURE TEST SYSTEM

2.1 As large a piping system as practicable including its associated equipment

shall be hydro tested together as a unit, unless the difference among their

design pressures exceeds 15 percents of the lowest design pressure of the

system components.

The test pressure in the system shall be equal to the test pressure applied to

the system component of which the design pressure is the lowest among the

system as mentioned in the following paragraph.

Where piping systems of different design pressures are fully welded together,

then "cascade" pressure testing will be required, (i.e. complete the pressure

test on the higher pressure system prior to system closure welding and then

repeat full Pressure Test Procedure for the test of the combined systems at

the lowest pressure).

2.2 Heat exchangers, pressure vessels and fired heaters may be included in a testsystem, providing the system test pressure does not exceed the shop test

pressure of any of the included items.


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2.3 The following equipment and components shall not be included in the system.

The equipment shall be isolated from the system.

2.3.1 Rotary equipment such as pumps, compressors and turbines.

2.3.2 Safety valves rupture discs, flame arrest's, and steam traps.

2.3.3 Pressure vessels with sophisticated internals.

2.3.4 Equipment and piping lined with refractoriness.

2.3.5 Storage tanks.

2.3.6 Filters, if filter element(s) is not dismantled.

2.3.7 Heat exchangers of which tube sheets and internals have been designed for

differential pressure between tube side and shell side.

2.3.8 Instruments such as control valves, pressure gages, level gages, and

flowmeter. (excluding thermocouples)

2.4 Exclusions

The followings are excluded from the requirements of this specification:

2.4.1 Any package unit previously tested by the manufacturer in accordance with

the applicable codes.

2.4.2 Plumbing systems, which are tested in accordance with the applicable

plumbing codes.

2.4.3 Lines and systems which are open to the atmosphere such as drain, vents,

open discharge of relief valve, and atmospheric sewers.

2.4.4 Instrument impulse lines between the block valve at the process or utility line

and the connected instrument.

2.5 Although instruments shall normally be excluded from the system, process

lead lines shall be tested to the first block valve together with the piping

system.


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Any vents or bypasses downstream of the instrument's first block valves shall

be opened or the instrument shall be disconnected during the test to insurefull protection of that instrument.

2.6 The test shall be hydrostatic using water, except if there is a possibility of

damage due to freezing, or if the operating fluid or piping material would be

adversely affected by water.

Any other suitable liquid shall be used with CONTRACTOR'S approval.

2.6.1 Testing on site with Kerosene or other inflammable fluids or compressed airshall be avoided as far as possible (except where specifically called for) and

shall be carried out only with the approval of CONTRACTOR.

2.6.2 If a flammable liquid is used, its flash point shall be not less than 50C and

consideration shall be given to the test environment.

2.7 Pneumatic testing shall be considered for the following;

2.7.1 Gas, steam, or vapor lines when the weight of the hydro test liquid would

overstress supporting structures or pipe wall.

2.7.2 Piping with linings subject to damage by the hydro test liquid.

2.7.3 The instrument air headers shall be tested with dry-oil free air. The commodity

test may be used if the systems are completed and the instrument air

compressor is operational.

3.0 TEST WATER CRITERIA

3.1 Care shall be taken to insure the use of clean water for hydrostatic tests. Andthe sea water is prohibited to be used.

A suitable filter should be provided in the filling line to the systems in order to

remove foreign matter such as sand, rust or other particles in the proposed

test water.

3.2 Hydrostatic testing shall be performed using clam potable water with a

chloride content of max 50 PPM for austenitic steels. In case this requirement

can't be fulfilled the pipeline shall be reamed completely and flushed with

water fulfilling the above requirement of 50 PPM max of chlorides.


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4.0 TESTING

4.1 Hydrostatic testing of piping designed for internal pressure

The minimum hydrostatic test pressure at any point in the system shall be as

follows.

(1) Not less than 1-1/2 times of the design pressure.

(2) For a design temperature above the test temperature, the

minimum test pressure shall be as calculated by the following

equation.

Where:

Pt = minimum calculated hydrostatic test pressure (kg/cm2)

P = internal design pressure (kg/cm2)

St = allowable stress at test temperature (kg/ cm2)

S = allowable stress at design temperature (kg/ cm2)

See Table I, Appendix A, IASME 831.3 1

When St and S are equal, test pressure is 1.5 x P.

Where the test pressure as defined above would produce a stress in excess of

the specified minimum yield strength at test temperature, the test pressure

shall be reduced to a pressure at which the stress will not exceed the

specified minimum yield strength at the test temperature.

The maximum test pressure at which the stress produced will not exceed the

specified minimum yield strength may be calculated by the following equation:

Where:

Pm = maximum test pressure (kg/ cm2)

S = specified minimum yield strength at test temperature (kg/

cm2)

t = specified pipe wall thickness minus mill tolerance (cm)

D = outside diameter (cm)

E = quality factor (see ASME B31.3 table A-1 B)

4.2 Hydrostatic testing of Piping Designed for External Pressure. (Jacked limes)


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4.2.1 Lines in external pressure service shall be subjected to an internal test

pressure of 1-1/2 times the external differential design pressure but not lessthan a gauge pressure of 1.055kg/m2 (15 psi).

4.2.2 Jacketed lines, the internal line shall be pressure tested on the basis of the

internal or external design pressure, whichever is critical.

This test shall be preformed prior to completion of the jacket.

4.2.3 The jacket shall be pressure tested of the basis to the jacket design

conditions.

4.2.4 Where systems require hydrostatic testing through static equipment, the test

pressure shall be selected so as not to exceed vessel test pressure.

5.0 BLINDS FOR PRESSURE TEST

5.1 Plain test blanks shall be used with 1/16 inch flat asbestos gaskets for

blanking flat face, and raised face.

Provide full face blanks and gaskets for CL 125 connections.

However, where permanent operational blinds are installed, they may be used

for pressure testing.

5.2 Plate material, extra length bolts and gaskets, which are made at the Job Sitecould be used for testing. Maximum allowable hydrostatic testing pressure for

test blinds refer to appendix I.

5.3 Temporary spades and blanks installed for testing purposes shall be designed

to withstand the test pressure without distortion. Temporary test spades and

blanks shall be readily identifiable by painting a red color on the handle.

5.4 For ring joint flanges, spare ring joints shall be required as they are to be used

only once.

6.0 TEST PACK PREPARATION

6.1 General

6.1.1 CONTRACTOR will prepare a marked up of P & ID indicating the test limits.


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6.1.2 From the marked up PID, Subcontractor will divide the piping into suitable

Test Packs. The size of the packs may be revised by Subcontractor providedthat the specification for limits in Clause 6.2 below is complied with.

CONTRACTOR shall be notified of such revisions and will authorize

Subcontractor to proceed if said revisions meet the specification.

6.2 Test Pack Limits

6.2.1 Subcontractor shall not test through equipment without CONTRACTORs

written approval.

6.3 Test Pack Format

(1) Pressure test report for Piping

(2) Marked-up PID

(3) Blind check list

(4) Welding History Report and Welding Joint Marked ISO Drawing

(5) NDE Report.

(6) PWHT and Hardness test Report

(7) Post Test Punch List (CONTRACTOR + Client)

(8) Copies of reinforcing pad pressure test certificates.(If necessary)

6.3.1 Test packs will include the latest available revision of each isometric covering

the scope of the test.

(1) Test limits, and highlight line to be tested.

(2) Size (thickness') and location of all test blinds and including those

required at instrument connections e.g. orifice flanges.

(3) Identify location for the connection of the fill and drainage points for

the system.

(4) Vent points

(5) Drain points

(6) Location and range of pressure gauges to be used. Minimum (2)

Calibrate gauges enquired, one located at an accessible low point of

the test and one gauge located at the highest points on the test

manifold.

(7) Any otherspecial requirements such as chloride content if applicable.

(8) If required, temporary supports shall also be indicated in the test pack

(9) Any control valve, check valve, safety valves or other piping

accessories requiring removal,turning, or some other action should be

highlighted.6.3.2 Test packs shall also contain copies of PID's marked-up to show at least the

following information:

(1) Piping Field Test Pack Number


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(2) Specific Limits of that Test Pack Only.

(3) Testing Medium i.e. water, dematerialized / condensate water,or visual.

(4) Hydrostatic Test Pressure.

(5) Location of Test Blinds, Isolation valve, and Temporary piping

6.4 Test Pack Approvals and Distribution

6.4.1 After compilation of the test pack, the "Original" shall be submitted for

approval by Subcontractor under cover of a transmittal memorandum to

attention of CONTRACTOR's Engineer.

6.4.2 CONTRACTOR's Engineer will review packs and sign them as "Approved", if

acceptable.

6.4.3 The "Original" pack will be returned to Subcontractor who will then distribute

one (1) copy to CONTRACTOR's Engineer and (1) copy to CONTRACTOR Q/C.

6.5 Field Change Sheet (FS for piping)

6.5.1 CONTRACTOR's Engineer shall check the status of the affected test pack and

advise subcontractor as follows:

(1) For test packs not yet hydro tested

Subcontractor shall amend the original of the test pack referencing the

FS and Re-distribute including the FS.

(2) For test packs where hydrostatic test completed

CONTRACTOR will over-stamp the original test pack with "RETEST"

The re-stamp original will then be returned to subcontractor under

memorandum with an instruction to carry out the retesting.

Redistribution will then proceed per 6.4.3 (above).

7.0 FIELD PIPE TESTING PROCEDURES

7.1 Piping Installation Completion

7.1.1 Upon completion of the piping system component installation and seven (7)

days prior to testing, Subcontractor shall submit original test pack toCONTRACTOR that Piping Test Pack Number is ready for mechanical

clearance..


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7.1.2 Prior to submitting said memorandum Subcontractor shall have inspected the

Piping Test Pack for its completeness of installation and have organized /reviewed all required documentation for Welding History, Post Weld Heat

Treatment and Non-Destructive Testing.

7.1.3 CONTRACTOR will inspect the Piping System with prepare punch list.

7.1.4 Only after CONTRACTOR have verified and endorsed welding QC clearance

on the test pack and cleared all "A" Punch List items from the CONTRACTOR

punch list, will PTT/Consultant be notified by formal transmittal of the

CONTRACTOR endorsed Test Pack. On receipt of the Test Pack,

PTT/Consultant will review and inspect the QC documentation and punch

piping pressure test system".

7.1.5 PTT/Consultant will review and verify welding QC clearance and punch the

piping system tested. Only after PTT/Consultant have endorsed the welding

QC as acceptable and punch list items have been cleared, will the Test Pack

be formally returned to CONTRACTOR endorsed "Released for Testing"

7.1.6 If PTT/Consultant identify deficiencies in the Test Pack documentation,

welding QC documentation and or outstanding class A punch list items, theTest Pack will be formally returned to CONTRACTOR complete with attached

punch lists to be corrected and signed prior to resubmittal.

7.2 QC Clearance

During the time the Punch List is being prepared, the CONTRACTOR's QC

Section and Subcontractor QC Section shall proceed as follows:

7.2.1 Alloy Verification (For stainless steel material)(1) Where applicable, Subcontractor QC Inspector shall confirm that all alloy

verification data is complete.

(2) After checking alloy verification documentation, the Subcontractor QC

Inspector shall notify CONTRACTOR's QC Engineer that the

documentation is complete for checking/ verification by CONTRACTOR,

which may be reviewed by Owner.

7.2.2 Post Weld Heat Treatment (PWHT) and Hardness Testing

When applicable, submission of data for PWHT and Hardness Testing shall

Review with test data.

7.2.3 Non Destructive Testing (NDT)


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(1) After checking NDT records the Subcontractor's Inspection Group shall

notify CONTRACTOR's QC Engineer that documentation is "Complete"for checking/verification by CONTRACTOR, which may be reviewed by

Owner.

(2) In addition, a visual check shall be carried out in the field by

Subcontractor and CONTRACTOR/Owner Inspection to ensure all

welding has been correctly performed and that no remedial work is

required. If there is remedial work required it should be recorded on the

Punch List.

7.2.4 CONTRACTOR's QC Clearance

If CONTRACTOR's QC Engineer and/or Owner's Area Welding Inspectors find

outstanding items during this review/inspection he shall add these welding

items to a separate

"Welding Punch List" maintained with the welding / tractability isometrics for

the Piping Field Test Report. When all items are completed to the satisfaction

of CONTRACTOR and Owner's Welding Inspectors he will then sign the

"Original" Piping Field Test Report as ready to test.

8.0 TESTING PREPARATIONS

8.1 All joints, including welds, shall be accessible and left uninstalled, unpainted

and exposed for examination during the test. Joints previously tested in

accordance with this specification may be insulated or covered.

8.2 Piping designed for vapor or gas shall be provided with additional temporary

supports, if necessary, to support the weight of the test liquid. Where

required, temporary supports shall be specified in the pressure test

documents.

8.3 Lines which are counterweight supported shall be temporarily blocked during

testing in order to sustain the weight of the test fluid. Spring hangers which

have been provided with stops for carrying the test load normally do not

require additional temporary supports:

If this is not the case, temporary support must be provided before filling the

system.

8.4 Before Testing

8.4.1 Piping systems shall have been completely checked for correctness.


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8.4.2 All lines, vessels and equipment shall be checked to insure the entire system

can be completely drained after testing.

8.4.3 Vents or other high point connections shall be opened to eliminate air from

lines which are to receive a hydrostatic test.

8.4.4 Temporary gaskets may be used, which are not the same as permanent

gaskets, provided.

(1) Such use will not lead to damage of the flange faces.

(2) Temporary gaskets are removed immediately after completion of tests.

8.5 Vessels that are to be tested through shall be-reviewed in order to determine

the best method to prevent air entrapment when filling and to prevent a

vacuum when draining.

8.6 Short pieces of piping which must be removed to permit installation of a blind

or blank shall be tested separately.

8.7 Lines containing check valves shall have the source of pressure located in the

piping upstream of the-check valve so that the pressure is applied under the

seat.

If this is not possible, remove or jack open the check valve closure mechanism

or remove check valve completely and provide necessary spool piece or

blinds.

A notation shall be included on the Punch List that check valve flapper has

been removed. A new gasket shall be installed by Subcontractor wherever the

check valve bonnet has been disturbed. Where flappers have been removed,

valves shall be marked by tagging.

8.8 Systems that include expansion joints:

8.8.1 Expansion joints shall be excluded from pressure testing if the piping test

pressure is greater than the allowable test pressure of the expansion joint.

8.8.2 When a pressure test is required to be maintained for a period of time during

which the testing medium in the system would be subject to thermal

expansion, provision shall be made for relief of any pressure greater than the

maximum pressure.

8.8.3 Holding pins/spring stops shall not be removed from spring supports or

hangers until testing is completed and permission to remove is obtained from

the CONTRACTOR.


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8.8.4 Test equipment to be used during testing shall have suitable capacity for the

range of test pressures required. The range of pressure gauge(s) shall not beless than 11/2 nor more than four times that pressure.

8.8.5 All pressure gauges and chart recorders are to be calibrated specifically for

OCS#4 Project prior to use. If gauges have been used previously on other

projects or for other purposes, they shall be recalibrated. Validation of gauges

and chart recorders shall be for a maximum of 90days, however, recalibration

shall be required if the calibrated gauge/recorder is damaged or strained.

8.8.6 If the specified test, duration exceeds 8 hours, then a chart recorder shall be

used to record test pressure.

8.8.7 Prior approval must be obtained from the CONTRACTOR and Owner to include

vessels or inline equipment in the pressure test circuit.

8.8.8 (1) All necessary precautions shall be taken to ensure that, where

applicable, nitrogen purges in vessels or equipment are maintained and

ingress of moisture prevented.

(2) Purges shall not be released without CONTRACTOR approval, and shall

be reinstated upon completion of required work, unless otherwisedirected by the CONTRACTOR.

8.8.9 No equipment/instrument that is part of permanent works shall be used as

part of pressure testing equipment (i.e. pressure gauges, chart recorders,

valves, safety valves etc)

9.0 HYDROSTATIC TEST PROCEDURE

9.1 A systems test shall be employed. So as to hydrostatically test as much

piping as possible at one time. This test shall include one or more lines but

should not be connected to vessels and equipments.

9.2 The minimum test pressure for a system test shall be such that each line in

the system is subjected to a minimum test pressure in accordance with

paragraphs 4.1 or 4.2

9.3 The maximum system test pressure shall not exceed the pressure test rating

of any piping component.

9.4 Systems or sections of systems to be tested may be isolated by closed valves

provided the alive seat is suitable for the test pressure.


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9.5 Where a valve is not suitable, vessels, equipment or other piping not included

in the system to be pressure tested shall be disconnected from the system orisolated by blinds or other means during the test.

9.6 The normal location for the pressure test gauge is at grade near the pressure

test pump and at the highest point of the piping system. Readings may be

made at higher points providing the gauge pressure reading plus the static

head (0.97 kg/cm2/M) between grade and the point of measurement does not

exceed the maximum test pressure.

9.7 Hydrostatic test pressure shall be maintained for a sufficient length of time to

visually determine if there are any leaks, but not less than ten (10) minutes.

Test pressure shall not be required to be maintained in excess of two hours

after notification to CONTRACTOR.

9.8 After completion of the test, pressure shall be released by opening the valve

gradually so as not to endanger personnel or damage equipment.

As a rule, pressure releasing rate shall be 300 kg/ cm2/hr. For piping line for

which pressure releasing rate is to be specified, refer to specific job

requirements.

9.9 After completion of the test, the piping and equipment shall be drained

completely.

9.10 Piping systems shall be filled from a low point and filtered with a 10 micron

filter. During filling of the system all air or gaseous substance shall be vented

from high point to the maximum extent possible.

9.11 Hydrostatic test water will be discharged to the nearest storm water drains.

10.0 SAFETY

The safety related issues including but not limited to the following should be

addressed in Job Hazard Analysis (JHA) to be made by CONTRACTOR for

performance of Pressure Testing activities:

10.1 Appointment of CONTRACTOR's Test Controller who is in attendance and

responsible throughout the testing and inspects the welding during testing.

10.2 Appointment of the subcontractor's test controller who will be responsible for

ensuring safe testing in accordance to the specification.


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10.3 Display of safety warning signs to alert workers in the vicinity of the pressure

testing with line, identification.

10.4 Pressure test training and maintenance of a competency register as required

by CONTRACTOR Safety Plan.

10.5 Pressure rating for the test manifold and the test equipment and the required

inspection/testing.

11.0 SENSITIVE LEAK TEST

Piping required to have a sensitive leak test shall be tested by the gas and

bubble formation testing method specified in article 10, section V, of the

ASME boiler and pressure vessel code. If an additional hydrostatic pressure

test is required, it shall be done after the sensitive leak test.

12.0 ALTERNATIVE TESTS

This test shall be applied in accordance with ASME B31.3 Para 344.9 or

ASME B31.4 Para 437.1.4(b), if required, subject to approval from

PTT/Consultant

12.1 Void

12.2 Void

12.3 Initial Service Leak test

12.3.1 This test is applicable only to piping in Category Fluid service at the

owner's option.

12.3.2 A piping system used only for category ID fluid service may be tested at

the normal operating conditions of the system during or prior to initial

operation by examining for leaks at every joint not previously hydrostatic

or pneumatic tested in accordance with this specification.

12.3.3 Unless dictated otherwise by contractual provision, commodity testingshall be performed before mechanical completion.


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12.4 Non Pressure Piping shall be checked thoroughly by visual examination in due

course after installation

13. VESSELS AND EQUIPMENT

13.1 Hydrostatic testing of the following items is not permitted. However, they

may be pneumatically tested with adjoining piping system, if so designated in

the Field Pressure Testing.

13.1.1 Vessels or equipment supported by other vessels or equipment or by a

support Structure or foundation not capable of supporting the hydro test

load.

13.1.2 Vessels or equipment not capable of sustaining the hydro test load.

13.1.3 Vessels with internals or linings that would be damaged by the test fluid.

13.2 The following shall be excluded from all pressure tests:13.2.1 Pumps, compressors and turbines. Associated lube and seal oil systems

which could be impaired by the presence of water shall be tested with lube

oil.

13.2.2 Equipment and Seller furnished piping specifically recommended by the

manufacturer not to be tested.

13.2.3 Strainer and filter elements.

13.2.4 Vessels which do not satisfy impact requirements at pressure test

temperature

14.0 INSTRUMENTS

14.1 All instruments will be protected from damage when hydro testing process

and utility piping systems. Paragraph 2.3 outlines the status of instruments

during testing to insure protection.

14.2 Control valves shall have their bodies shop tested and need not be retested in

the field, but where valve does not restrict test pressure, valve may be

included in a system test. Valves shall be jacked open during test.


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15.0 CLEANING

15.1 Tested piping shall be internally cleaned to remove all remaining dust and

foreign matter by water flushing or blowing with air.

15.2 Flushing shall be done with clean water using hydrostatic test water where

possible. Water used for special flushing or cleaning of austenitic stainless

steel shall not contain more than 50 PPM chlorides, i.e.

15.3 Where special treatment is required, such as cleaning of compressor suction

and lube oil piping, a separate procedure shall be prepared by

CONTRACTOR'S Operations/Commissioning Group.

16.0 REPORTS AND RECORDS

16.1 As a minimum, the Subcontractor shall maintain records of all pressure tests,

records of all welding operations, including welder numbers, weld numbers,

and post weld heat treatment charts referenced to weld numbers, records of

all hardness tests, records of all cleaning, pressure gauges calibration sheets,

and when certification is required, all certification records.

16.2 All records shall be submitted and approved by the CONTRACTOR and shall

be submitted to the Owner.

16.3 Piping Field Test Report shall be prepared for each line segment of non

pressure piping.

17.0 TEST RECORDS

17.1 Records shall be made of each piping system test.

These records, when completed, shall be submitted as part of the test and

inspection certificates which are required for precommisioning.

Records shall include:

1) Date of test

2) Identification of piping system and any vessels or equipment tested

with the piping system.

3) Test medium

4) Test pressure and maintaining time

5) Minimum ambient temperature


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17.2 All test records, and authorized CONTRACTOR certifications shall be retained

in the Test Package records for turnover to the Owner. Test data base shall beestablished to monitor status and progress.

17.3 Where complete drainage is impossible, the system shall be flushed free of all

test water using boiler condensate or dematerialized water containing less

than five(5) PPM chlorides, alcohol, petroleum distillate or another suitable

flushing solution. Hot air drying is not acceptable in lieu of flushing, but water

may be blown out of pockets using air.


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Appendix I Minimum Thickness of Blank for Pressure test


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1. In case where piping diameter is 1B or under.

Test Pressure (kg / cm2) Thickness of Blind Plate (mm)

7 or under 1.6

8 14 2.3

15 40 2.5

41 60 3.2

61 115 4.5

116 210 6.0

2. In case where piping diameter is 26B or over, following formula shall be

applied to determine the thickness of blind plate.

Thickness of blind plate tm = t + c

dg : Inside diameter of gasket (mm) for raised face flanges, or the gasket

pitch diameter for ring joint and fully retained gasket flanges(inches)

P : design gauge pressure (psig)

S : stress value for material from Table A-1 B (psig)

E: quality factor from table A-1A or A-1 B

C : corrosion / erosion, plus mill tolerance allowance(inches)


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Appendix II. Details of Test Facilities

Schematic DWG for Supplying Source

(1) For Pneumatic Test (Not applicable)

(2) For Hydrostatic Test

Equipment List for Piping Pressure Test.

(1) Pump

- Test Pump (Pressurizing Rump)

- Water Supply Pump

(2) Air Compressor (for blowing, if required)

(3) Pressure Gauge (Two (2) or more)

(4) Rubber Hose W/Steel Wire Reinforced

(5) Temporary Piping with accessory

(6) Chemical Inhibitor (If required)

(7) Radios (Warlike Talkie)

(8) Other materials


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Appendix III. Test Limits Symbol

(1) Pressure Gauge hall be used and having graduation of 1.5 or 2 times of

test of more including gauge in pump discharge.

(2) PG shall be installed two or more including gauge in pump discharge.

(3) Calibrated gauge shall be used.

(4) Gauge be installed at the highest and the lowest point.

PTT_ Hydro Static Pressure Testing of Piping

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