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Inspection and Testing of Piping Systems

ES-14-602-02

This is a Controlled Document that complies with CSBP Limited formatting and QualityControl guidelines. Please check that this is the latest available version before use.

Title: INSPECTION AND TESTING OF PIPING SYSTEMS

Number: ES-14-602-02

Owner: Phillip Brown

Authoriser: David Zacher

Version Details: Additional references to Stage 1 Commissioning Inspection Reportsadded, requirement to lock spring supports if test medium density isdifferent to operating density, additional test dispensation examplegiven and one spelling correction.

Refer sections

TABLE OF CONTENTS

1. SCOPE .................................................. ............................................................ .....................................3

1.1 DEFINITION OF TERMS ....................................................... .........................................................3 2. APPLICABLE CODES AND STANDARDS ......................................................... ............................4

2.1 CSBP ENGINEERING STANDARDS AND PROCEDURES ........................................................4 2.2 CSBP GUIDE MANUALS ...................................................... .........................................................4 2.3 CSBP STANDARD FORMS ................................................... .........................................................4 2.4 ASTM: AMERICAN SOCIETY FOR TESTING AND MATERIALS ..........................................5 2.5 API: AMERICAN PETROLEUM INSTITUTE ................................................... ............................5 2.6 ANSI: AMERICAN NATIONAL STANDARDS INSTITUTE / ASME: AMERICAN SOCIETY

OF MECHANICAL ENGINEERS................................................................................................................6 2.7 ASME: AMERICAN SOCIETY OF MECHANICAL ENGINEERS ..............................................6 2.8 STANDARDS ASSOCIATION OF AUSTRALIA ........................................................ ..................6 2.9 OTHER ASSOCIATIONS................................................................................................................7

3. QUALITY SYSTEMS ....................................................... ........................................................... ........7 3.1 QUALITY PLANS............................................................................................................................7




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5. STAGE 1 - INSPECTION AND CONSTRUCTION VERIFICATION ........................................13 5.1 NON DESTRUCTIVE EXAMINATION - PIPING AND FITTINGS...........................................13 5.2 BRANCH WELDS AND REINFORCING PADS ......................................................... ................16 5.3 HARDNESS TESTING ........................................................... .......................................................16

6. STAGE 2 - TESTING ........................................................ ........................................................... ......16 6.1 PUNCHLISTING PIPING SYSTEMS ........................................................ ...................................17 6.2 SYSTEM FLUSHING.....................................................................................................................19 6.3

WITNESSING PIPING SYSTEM PRESSURE TESTING...................................................... ......20

6.4 HYDROSTATIC TESTING .................................................... .......................................................20 6.5 SYSTEM DRYING.........................................................................................................................25 6.6 CHEMICAL CLEANING OF PIPING SYSTEMS ........................................................ ................25 6.7 PNEUMATIC TEST PROCEDURES ......................................................... ...................................26 6.8 LEAK TESTING OF PIPING SYSTEMS......................................................................................26 6.9 AIR BLOWING OF PROCESS PIPEWORK.................................................................................31 6.10 STEAM BLOWING OF TURBINE PIPEWORK .......................................................... ................32 6.11 SETTING SPRING PIPE SUPPORTS ........................................................ ...................................34 6.12 RE-INSTATEMENT OF PIPING SYSTEMS................................................................................34 6.13 NITROGEN PURGING..................................................................................................................35 6.14 PIPING TIE-INS TO EXISTING PLANT......................................................................................35 6.15 POST COMMISSIONING CHECKS .......................................................... ...................................35

APPENDIX 1 - FLUID SERVICE PIPING SYSTEM INSPECTION CLASSIFICATION FLOWCHART .................................................. ............................................................ .............................................36

APPENDIX 2 - COMMISSIONING ACTIVITY - AIR BLOW (EXAMPLE) ........................................37

APPENDIX 3 –COMMISSIONING ACTIVITY - STEAM BLOW (EXAMPLE)..................................39

APPENDIX 4- AUTHORISATION TO TEST THROUGH A VESSEL (EXAMPLE)...........................40

APPENDIX 5 - PIPING TEST PACK INDEX....... ........................................................... ..........................42

APPENDIX 6 - INSPECTION & TEST LOG BOOK ...................................................... ..........................43

APPENDIX 7 - PIPING FIELD TEST REPORT .................................................... ...................................44

TABLES

TABLE 1 NON DESTRUCTIVE EXAMINATION ........................................................ ............................................ 15




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2. APPLICABLE CODES AND STANDARDS

The Contractor shall perform the works in accordance with the most recent issue of the applicablestandards and codes issued by the following:

a. CSBP Engineering Standards

b. American National Standards Institute (ANSI)

c. American Petroleum Institute (API)

d. American Society of Mechanical Engineers (ASME)

e. American Society for Testing and Materials (ASTM)

f. Manufacturer’s Standardisation Society of the Valve and Fittings Industry (MSS)

g. Standards Association of Australia (SAA)

h. Other Associations (as nominated)

2.1 CSBP ENGINEERING STANDARDS AND PROCEDURES

ES-14-102-14 Insulation of Piping and Equipment

ES-14-601-01 Basis for Design - Piping

ES-14-602-01 Fabrication and Installation of Piping

ES-14-603-01 Piping Material Specifications

ES-14-603-02 Valve Specifications for Process Isolation

EP-08-030-19 Engineering Project Design Review.

EP-08-030-37 Manufacturers Data Report (MDR) – Plant Projects

2.2 CSBP GUIDE MANUALS

GM-11-031-23 “Take 5” and Job Safety Analysis Risk Assessment

2.3 CSBP STANDARD FORMS

Stage 1 Commissioning Inspection Reports

M146 PipelinesM147 Pipeline Valve Operation




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2.4 ASTM: AMERICAN SOCIETY FOR TESTING AND MATERIALS

A53 Welded and Seamless Steel Pipe

A105 Forged or Rolled Steel Pipe Flanges, Forged Fittings, and Valves and Parts forHigh Temperature Service

A106 Seamless Carbon Steel Pipe for High Temperature Service

A181 Forged or Rolled Steel Pipe Flanges, Forged Fittings, and Valves and Parts forGeneral Service

A182 Forged or Rolled Alloy - Steel Pipe Flanges, Forged Fittings, and Valves and Partsfor High-Temperature Service

A193 Alloy - Steel and Stainless Steel Bolting Materials

A194 Carbon & Alloy Steel Nuts for High-Pressure & High-Temperature Service

A216 Carbon Steel Castings Suitable for Fusion Welding for High-Temperature Service

A234 Factory-Made Wrought Carbon Steel and Ferritic Alloy Steel Welding Fittings

A312 Seamless & Welded Austenitic Stainless Steel Pipes

A333 Seamless & Welded Steel Pipe for Low-Temperature Service

A335 Seamless & Welded Steel Alloy-Steel Pipe for High-Temperature Service

A350 Forgings, Carbon and Low-Alloy Steel, Requiring Notch Toughness for PipingComponents

A403 Wrought Austenitic Stainless Steel Piping Fittings

2.5 API: AMERICAN PETROLEUM INSTITUTE

5L Line Pipe

6D Pipeline Valves (Gate, Plug, Ball, Check Valves)

6FA Fire Test for Valves594 Wafer and Wafer-Lug Check Valves

597 Steel Venturi Gate Valves

598 Valve Inspection and Testing

599 Metal Plug Valves - Flanged and Welding Ends




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2.6 ANSI: AMERICAN NATIONAL STANDARDS INSTITUTE / ASME:AMERICAN SOCIETY OF MECHANICAL ENGINEERS

B1.20.1 Pipe Threads

B16.5 Pipe Flanges and Flanged Fittings

B16.9 Factory Made Wrought Steel Buttwelding Fittings

B16.11 Forged Fittings, Socket - Welding and Threaded

B16.20 Metallic Gaskets for Pipe Flanges - Ring Joint, Spiral Wounds and Jacketed

B16.25 Buttwelding Ends

B16.34 Valves - Flanged, Threaded and Welding end

B16.47 Large Diameter Steel Flanges

B36.10 Welded and Seamless Wrought Steel Pipe

B36.19 Stainless Steel Pipe

2.7 ASME: AMERICAN SOCIETY OF MECHANICAL ENGINEERS

Boiler and Pressure Vessel Codes:

Section V - NDT

Section VIII - Pressure Vessels Divisions 1 and 2

Section IX - Welding and Brazing QualificationsB31.3 Chemical Plant and Petroleum Refinery Piping

2.8 STANDARDS ASSOCIATION OF AUSTRALIA

AS 1074 Steel Tubes and Tubulars for Ordinary Service

AS 1111 ISO Metric Commercial Hexagon Bolts and Screws

AS 1112 ISO Metric Hexagon Nuts

AS 1170 Part 4: Earthquake Loads

AS 1432 Copper Tubes for Plumbing, Gas Fitting and Drainage Applications

AS 1627 Metal Finishing - Preparation and Pretreatment of Surfaces




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AS 3679 Structural SteelAS 3788 Pressure Equipment - In Service Inspection

AS 4041 Pressure Piping

AS 4100 Steel Structures

2.9 OTHER ASSOCIATIONS

MSS SP 25 Standard Marking Systems for Valves, Fittings, Flanges and Unions

MSS SP 55 Quality Standard for Steel Castings for Valves, Flanges and Fittings and otherPiping Components (visual method)

BS6755 Part 2 - Specification for Fire Type - Testing Requirements

3. QUALITY SYSTEMS

Unless otherwise approved by the Superintendent, the Contractor’s Quality System shall complywith the requirements of the international standard ISO 9001 for the work under the Contract.Where the Contractor has certification of such compliance from an accredited organisation, a copyof the certificate shall be provided to the Superintendent upon request. The Contractor shall alsoprovide to the Superintendent such information as the Superintendent may require to demonstratethat his/her systems and procedures comply with the philosophy and intent of that Standard.

Where the Contractor is not the manufacturer of material for work under the Contract, theContractor shall ensure that the manufacturer(s) comply with all specified QA requirements.

The Superintendent may audit the Contractor’s or Subcontractor’s Quality System at any time. TheContractor shall assist in carrying out such audits and shall rectify any deficiency identified by thedate specified by the Superintendent.

The Contractor shall also provide copies of any documentation the Superintendent may require to

verify the adequacy and effectiveness of the Quality System, including calibration certificates, forany equipment used in testing or verifying the adequacy of the work under the Contract.

3.1 QUALITY PLANS

The Quality Plan shall detail the responsibilities of all personnel critical to the performance of thek d h C




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3.5 CERTIFICATION OF MATERIALS TEST DATA

The following types of certificates are specified to verify that the requirements of the Contract aremet:

Type I: (Equivalent to DIN 50049-2.2)

Certificates on which the Contractor confirms, on the basis of the test results from the in-

production testing of products of the same material and same manufacturing method as theequipment concerned, that the equipment supplied corresponds with what was specified.

Type II: (Equivalent to DIN 50049-3.1B)

Certificates on which the Contractor’s inspector confirms, on the basis of tests carried out on theequipment itself or on standard specified test specimens related to the equipment, that theequipment supplied corresponds with what was specified. A testing centre that has no connectionwith the production in the manufacturing works and which has the necessary facilities at itsdisposal must have carried out the necessary testing. When the independence of the testing centreis not warranted a Type III certificate shall be submitted.

Type III: (Equivalent to DIN 50049-3.1C)

As for Type II Certificates except tests shall be witnessed by an independent inspector approved bySuperintendent and the certificates stamped and signed by this inspector for acceptance.

All certificates shall contain the following information:a. Name of manufacturer,

b. Purchase order number and date,

c. Manufacturer’s order number,

d. Certificate identification number and date of issue,

e. Material specification,

f. Dimensions if applicable,

g. Charge number - batch number or heat-lot-number,

h. Chemical composition from test results,

i. Mechanical properties from test results,




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3.6 INSPECTION BY THE SUPERINTENDENT

The Contractor will specify on the ITPs the inspections and tests at which the Superintendent willattend. The Contractor shall provide at least five (5) days notice in writing of the inspections ortest dates for procedures to be witnessed in Australia and fourteen (14) days for overseas.

Notwithstanding the tests and inspections specified for the Superintendents attendance, theSuperintendent reserves the right to inspect any part or the whole of the work under the Contract

during or on completion of manufacture and erection.

Every facility shall be provided by the Contractor to enable the Superintendent to carry out thenecessary inspections.

4. PRELIMINARY ACTIVITIES

4.1 DESIGN REVIEW

The Contractor shall carry out a design review in order to facilitate inspection and testing work anddefining the approach to be taken.

When all HAZOP studies and CSBP Design Reviews have been completed and the P&ID’s are at astage where they have been “frozen” the Contractor shall:

a. Review and mark up P&ID’s to determine extent of each Test Pack and to define totalnumber of Packs.

b. Determine which vessels can be pressure tested “through” and which cannot (review 70%rule and confirm that structure/ foundations have been designed to accommodate the weightof water filled lines and vessels).

c. Consider flanging of vessel nozzles to simplify testing work.

d. Rationalise Piping system test pressures to minimise the total number of Test Packsrequired as a result of maximising test limits.

e. Prepare a master set of colour coded P&ID’s to identify Test Packs and boundaries.f. Revise the Line List to reflect rationalised test pressures.

g. Revise the Line List to include a Test Pack Number against every line.

h. Revise Isometrics to reflect rationalised test pressures where required.

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4.2 TEST PACK

4.2.1 Create Master Test Pack

The Contractor shall create a Master Test Pack to collect and collate all information required tomake up complete test packs. Each Master Test Pack, for the systems identified by the Contractorduring the Design Review, shall include the following minimum information:

a. Test Pack lead sheet identifying Line Number, Isometric Number, P&ID Number, Testmedium, Test pressure and extent of test.

b. Marked up a set of P&ID’s identifying Test Pack and delineating test boundaries.

c. Authorisation sheet allowing vessel to be included in test (where applicable). Refer toAPPENDIX 4 for example.

d. Stored energy calculations/exclusion zone distances for pneumatic tests as per AS3788Appendix D.

Once complete, the “Master Test Pack” shall be submitted to the Superintendent for approval.

4.2.2 Completion of Test Packs by Contractor

The Contractor shall complete the Master Test Pack to include a marked up set of isometricsshowing:

a. Limit of test,

b. Location, size and rating of blind flanges,

c. Location, size and thickness of test spades,

d. Test fill location,

e. Test vent location(s),

f. Test pressure gauge locations,

g. Relief valve set pressure (for pneumatic tests), and

h. Exclusion zone definition and location of barriers shown on a plot plan of the area (forpneumatic tests).

The Contractor shall submit the Master copy of each Test Pack to the Superintendent foracceptance.




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4.2.2.1 Test Pack Identification Colours

For ease of identification Test Packs shall be colour coded. An example is as follows:

Master Test Pack : Blue Folder

Welding/Traceability Test Pack : Green Folder

CSBP’s copy (2 required) : Buff Folder

Contractor’s copy : Purple Folder TestingContractor’s copy : Red Folder

Spare/Working Field Copies : Yellow Folder

4.3 CSBP DESIGN REVIEW

At the end of the design phase CSBP shall conduct an Operability and Maintenance review as perCSBP Engineering Procedure Engineering Project Design Review (EP-08-030-19)

This review is designed to supplement the HAZAN & HAZOP studies and identify any areaswhere a hazard exists in the day to day operation of the plant.

Should the Contractor discover during the course of assembly and erection of equipment thatoperational or maintenance difficulties may be encountered in the future the Contractor shall bringit to the Superintendent’s attention immediately.

4.4 OPERATOR TRAINING

During the final stages of Construction, the Superintendent shall commence Operator trainingactivities. Whilst this does not impact Contractor’s scope of work there may be areas whereContractor can impart specialised knowledge or information regarding equipment to CSBPpersonnel.

4.5 SAFETY SYSTEM CHECKS

It is the Contractors responsibility to perform all work in a safe manner and to identify allpotentially hazardous activities. A Job Safety Analysis (JSA) review shall be carried out prior tostarting work. The Contractor shall submit the JSA record to the Superintendent for approval priorto commencing the activity, which was the subject of the JSA. For guidance, refer to CSBPdocument “Take 5” and Job Safety Analysis Risk Assessment (GM-11-031-23) .




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All nozzle welds and structural attachment welds shall be dressed to a reasonably smooth finish,free from undercut and merge smoothly into the pipe surface without any sharp corners or otherstress raisers.

The following items shall be checked for compliance with CSBP Engineering Standard Fabricationand Installation of Piping (ES-14-602-01) for all fabrication work:

a. Correct storage of welding consumables.

b. Quality of weld preparation including cleanliness, alignment, preheating, and tack welds.

c. Adequate protection against bad weather conditions.

d. Correct procedures followed during interruptions in welding, especially when preheating isinvolved or root bead only is deposited.

e. Appearance of weld, including reinforcement and dressing of the weld surface.

f. Quality of welding repairs.

g.

Correct heat treatment.h. Correct gaskets fitted in flanged joints.

i. Correct studs fitted in flanged joints.

j. All flanged joints fully tightened.




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Inspection Class Visual Radiographic orUltrasonic Radiographic MPI/Dye Penetrant (A)

1 (G) 100%

2 (E) (F) (D) 100% 5% (C) (H) 5% (C) (H)

3 (E) (D) 100% 20% (C) (I) 20% (C) (I)

4 (E) (F) 100% 100% 100%

5 (E) 100% 100% (B) 100%

6 100%

7 (G) 100%

LEGEND

(A) Magnetic particle inspection (MPI) or dye penetrant testing is only required where weld CANNOT beradiographed, except where note (E) applies.

(B) Ultrasonic testing is NOT a substitute for radiography but it can be used to supplement it.

(C) All welders work and all line sizes to be to be represented at % given.

(D) All tie-in welds to be represented.

(E) With the exception of “Non Hazardous” fluids, all welds, which CANNOT be hydrotested shall be subjectto full visual, radiographic, ultrasonic (for 12mm thickness and above) and MPI/Dye Penetrantexamination.

(F) Inner process pipe of jacketed lines to be examined in accordance with Inspection Class 4. Associatedouter pipe to be in accordance with class specified for the jacketing fluid in CSBP Engineering StandardBasis for Design - Piping (ES-14-601-01) .

(G) When approved by the Superintendent, piping systems for “Non Hazardous” fluid service (Category DASME B31.3) can be subject to an initial service leak test in lieu of hydrostatic testing.

(H) Increase to 20% for “in position” welds. These are to be in addition to the 5% required for other welds.

(I) Increase to 100% for “in position” welds. These are to be in addition to the 20% required for other welds.




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5.2 BRANCH WELDS AND REINFORCING PADS

Special care shall be taken in the inspection of branch welds, weldolets and reinforcing pad welds.All branches shall be properly fitted to assure the production of sound welds. Branch welds shallmerge smoothly with the surface of the pipe with no notches or undercutting permitted. Sharpcorners on reinforcing pads shall be removed.

5.3 HARDNESS TESTING

Brinnell hardness testing shall be performed on heat-treated welds in accordance with ASMEB31.3, plus as specified in section 4 of Fabrication and Erection of Piping (ES-14-602-01).

Hardness tests are not required on welds for which it is not possible to perform a test.

The acceptance criteria shall be as per ASME B31.3, except that where the code does not specify acriteria (e.g. carbon steel), then the maximum hardness shall be as specified in section 4 of Fabrication and Installation of Piping (ES-14-602-01) .

6. STAGE 2 - TESTING

All piping shall be pressure tested except for:

a. Lines and systems which are open to the atmosphere, such as drains, vents, and atmosphericsewers, unless noted otherwise on design documentation

b. Where the Superintendent, Area Plant Engineer, and Senior Plant Inspector have authorisedthat no test is required. The approval of the pressure testing waiver and the reason for thewaiver shall be recorded on the ITP or other quality documentation included in the MDR.

Note: When approved by the Superintendent, piping system for “Non Hazardous” fluid service(Category D ASME B31.3) can be subject to an initial service leak test in lieu of hydrostatic testing.

Pressure testing for metallic piping shall be in accordance with ASME B31.3 and as specified inthis Standard. The test pressures shall be as indicated on the piping isometrics/line list.

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e. Test pressure gauges have been calibrated and correctly installed.f. Calibration certificates for test gauges and relief valves are current.

g. Lock spring supports if the test medium has a different density to the fluid in the piping innormal operation.

h. All inline instruments have been removed (except thermowells) and signal and impulselines disconnected.

i. All vents, drains and primary instrument connections have been plugged / capped and allvalves are open.

j. All control valves have been removed and stored in a safe location with flange facesprotected.

k. All equipment has been spaded off and precautions taken to ensure that test or flushingwater cannot enter equipment. (especially compressors) Testing through equipment is byexception only.

l. All relief valves have been spaded off or removed to a safe location with flange faces

protected.m. Pneumatic test access barriers are in place and the Superintendent’s Safety Department

notified.

A test may not proceed until both the Superintendent’s Fabrication Inspector andPiping/Mechanical Engineer have signed the PFTR.

In addition to notification in the Inspection and Test Plan, the Contractor shall advise the

Superintendent of test by making entry in Inspection and Testing Log Book a minimum of forty-eight hours prior to hydrotest and five working days in the case of a pneumatic test. Refer toAPPENDIX 6 for example Inspection and Testing Log Book.

6.1.2 Post Test Punchlisting and Reinstatement Pack

Post test punch listing is a complete and comprehensive review of each piping system.

Following successful testing, the Contractor shall reinstate piping systems by removing testspades/blinds etc. and re-instate all in-line instruments and valves. The Superintendent shall thenprepare a Post Test Punch List and submit this to the Contractor for prompt execution.

The punchlist shall be prepared by examining the piping system against the Stage 2 CommissioningReports: Pipelines ( M246 ) and Pipeline Valve Operation ( M247 ). To supplement the Stage 2C i i i R t th C t t h ll i t t t k t ith t t




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c. A list of special items which may not be obvious to the person reinstating the pipingsystem. Such items may include:

1. Reinstallation of thermowells.

2. Reinstallation of internals of items such as non-return valves and steam traps.

3. Noting of drilling of ball or plug valves and which end the hole should be.

4. Checking of pipe support guide clearances.

5. Removal of spring support locks/chocks.6. Post commissioning spring support hot set check and adjustments.

Where there is no test pack for a piping system, then a reinstatement pack shall still be preparedusing the latest revision of the piping drawings to check that the final installation is correct.

Reinstallation packs shall be submitted for approval to the Superintendent

The Contractor shall maintain a record of testing and provide a weekly report indicating thenumber of post test punchlists issued, total number of punchlist items, how many were cleared inthe last week and total number outstanding.

An example Piping Test Pack Index can be found in APPENDIX 5.

The Contractor shall supply a copy of all calibration certificates for the Master Test Pack. Gaugesshall be inspected for defects and to ensure proper working order. Contractor shall have available a

range of test gauges to cover all test pressure requirements within his scope of work.A chart pressure recorder and temperature recorder shall be used for all pneumatic tests. Theoriginal chart record of pressure versus time, and temperature versus time shall be included in theMaster Test Pack. Unless otherwise agreed by the Superintendent a chart recorder shall be used forhydrostatic tests.

6.2 SYSTEM FLUSHING

All lines and attached equipment shall be thoroughly flushed and cleaned with the testing medium,before testing takes place.

Pipework shall have the inlet located at the highest point such that each branch is thoroughlyflushed. On large and diverse systems, several return lines to the tanker may be necessary.




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Flushing by air shall be subject to approval by the Superintendent. Where used, except as definedin Section 6.9, Contractor shall ensure that volume is sufficient to blow out any debris. Exitlocations for air blowing shall be chosen to ensure safety of personnel and consideration shall begiven to the noise emitted during this activity.

6.3 WITNESSING PIPING SYSTEM PRESSURE TESTING

6.3.1 Request to Witness a Test

In addition to notification in the Inspection and Test Plan, the Contractor shall make an entry in the“Inspection and Testing Log Book” at least 48 hours before a hydrotest and at least five (5) daysbefore a pneumatic test.

An example of the Inspection and Testing Log Book can be found in APPENDIX 6.

6.3.2 Witnessing a Pressure test

Following acceptance of line flushing, Contractor shall reconfigure system for a pressure test.Hydrotests shall be filled from low point, with high point vents opened to allow air to escape.

During a hydrotest, the immediate area shall be isolated using bunting, which carries a safetywarning and advises that a pressure test is being conducted. Refer to Section 6 for guidelines onexclusion distances.

Pneumatic tests require an exclusion zone, refer Section 6.7 . The Contractor shall schedule

pneumatic tests to ensure that the exclusion zone is kept clear of all personnel during systempressurisation and only those personnel directly involved with the test may enter to conduct andwitness the soap tests at designated “hold” periods.

Contractor shall provide safe access to every weld / screwed connection for the Superintendent’sInspector.

All pressure tests shall be witnessed by an approved NATA endorsed Inspector and by theSuperintendent, at his discretion.

Following examination and acceptance of the system, the recorder charts and the PTFR in theMaster Test Pack shall be signed off.

Within 24 hours, Contractor shall bind original charts, and copies of all relevant calibrationcertificates together with any other pertinent documentation into the Master Test Pack




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Continuous pressure and temperature recorders shall be supplied by the Contractor and used torecord pressure and temperature during the test period.

Equipment to be used during testing shall have suitable capacity for the range of test pressuresrequired. Pressure indicators shall have a full-scale range between 110 percent and 150 percent of test pressure and an accuracy and sensitivity of 2 percent of full-scale reading. All pressure gaugesand chart recorders shall have current calibration certificates endorsed by a NATA approvedauthority.

A minimum of two gauges shall be provided for each test system. One shall be located at thehighest point and one located at the pump at grade. A gauge shall also be located at the extremityof each system unless otherwise agreed by the Superintendent.

6.4.2 Contractor Obligations

The Contractor shall submit comprehensive testing procedures and schedules both for hydrostaticand pneumatic testing, to the Superintendent for his approval prior to start of testing.

It is the Contractor’s responsibility to satisfy the Superintendent that procedures will not result inany damage or deformity to the piping or the equipment and they incorporate all safetyrequirements.

Approval of the procedure by the Superintendent does not absolve the Contractor from theresponsibility of workmanship, quality compliance with the Code requirements and safetyconsiderations.

The Contractor shall review drawings and pipework prior to pressure testing to ensure thatsufficient vents, drains, blind flanges, etc, are installed to carry out the hydrostatic testingprocedures. All high points must be vented and low points capable of being drained. TheContractor shall provide any additional vents and drains that are required in accordance with theapplicable piping specification.

Any errors, discrepancies or omissions on the drawings shall not relieve the Contractor of theresponsibility for pressure testing the pipework in accordance with the intent of this Standard. Anysuch error, discrepancy or omission shall be brought to the attention of the Superintendent for aninterpretation or ruling.

6.4.3 Equipment Isolation

Equipment such as pumps compressors blowers turbines other rotating machinery and vessels




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Piping shall be tested prior to installation of inline items such as relief valves, control valves,rupture discs, displacement and turbine meters, orifice plates, flow nozzles, level gauges,rotameters, strainers, etc, or the connection of instruments to the piping system to be tested. If it isnot practicable to perform testing prior to installation of inline items, it shall be Contractor’sresponsibility to remove or disconnect these items so those tests can be performed and to re-installsuch items after testing. Sealing and plugging for testing of systems after removal of inline itemsshall be performed by contractor. Contractor shall remove sealing and plugging items aftercompletion of testing and shall re-install the inline items.

6.4.4 Valve Configuration

The operation, settings and ratings of all safety valves/relief valves and rupture discs shall bechecked and tested in accordance with ASME B31.3.

All gate, globe and butterfly valves shall be tested in the open position unless otherwise specifiedon the piping isometric. Ball valves shall be tested in the half-open position.

Piping containing check valves shall have the pressure source located on the upstream side of thevalve and the drain on the downstream side of the valve. Where this is not possible, check valveinternals shall be removed for testing. A new gasket shall be installed if the valve bonnet has beenremoved after completion of testing.

6.4.5 Joints

All joints in the piping system shall be accessible during tests and shall not be insulated, back-filled

or otherwise covered until satisfactory completion of testing in accordance with this Standard. Anyprotective tape applied to shop welds in carbon steel spools shall be removed prior to pressuretesting.

The breaking of joints to insert blanks for testing should be kept to a minimum.

Sealing materials shall not be used to correct leaks at joints. Valve glands shall not be tightened tothe extent that the valve cannot be operated. If directed by the Superintendent valves shall berepacked.

6.4.6 Loading Considerations

Care shall be taken to avoid overloading any part of the pipe support system or supportingstructures. Large piping designed for vapour or gas shall be provided with additional temporarysupports if necessary to support the weight of the test fluid




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6.4.8

Steam JacketingThe jacket of jacketed lines shall be tested as described in ASME B31.3. If the test pressure in the

jacket is too high for the internal lines as an external pressure, the internal line shall be pressurisedto minimise the differential pressure.

6.4.9 Venting

The Contractor shall be responsible for the venting of all sections of the piping system and shallmake every effort to ensure removal of trapped air to the satisfaction of the Superintendent.

6.4.10 Testing Medium

For hydrostatic testing of carbon steel piping systems the test medium shall be potable water atambient temperature with pH value between 6 and 7.

For hydrostatic testing of piping systems that are wholly or partially fabricated from austenitic

stainless steel piping components the test medium shall be demineralised water with a chloridecontent of maximum 1 ppm and pH value between 6 and 7. Water shall be drained immediatelyafter hydrostatic testing.

A report on water analysis including the chloride content and pH value of the water shall beattached to the test report at all times when austenitic stainless steel systems are hydrotested. Acertified and recognised laboratory shall prepare the analysis and report.

6.4.11 Test Pressure

In accordance with ASME B31.3 the minimum hydrostatic test pressure at any point in the systemshall be:

a. 1.5 times the design pressure, or

b. calculated in accordance with formula specified in ASME B31.3 if the design temperatureis above the test temperature.

The test pressure for non-metallic piping shall be in accordance with the piping manufacturer’srecommendations and the applicable Australian or international standard covering installation andtesting of the piping material

6.4.12 Test Duration

I i d T i f Pi i S




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b.

One (1) hour for pipework where:1. Not all sections of the pipework are visible.

2. The pipe is not easy to inspect.

3. Volume is relatively large.

4. System of pipework being tested is long and complex.

5. Extra thick walled pipe is being tested.

c. As determined and specified by the Superintendent to suit any circumstances but not lessthan ‘a’ or ‘b’ above.

6.4.13 Rectification

The Contractor shall be responsible for rectification work of damage, resulting from test pressuresbeing more than ten (10) percent higher than those specified on the Piping Isometrics and Line List.

6.4.14 Examples of Hydrostatic Testing Dispensations That May be Approved

Refer to the beginning of Section 6 for approval of these dispensations and what needs to berecorded.

The following examples of dispensations that might be granted, only apply to work covered by,Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks (DP-05-095-06) .

1. One test gauge is allowable as long as it is located so it will measure the maximumpressure in the system during the test.

2. A chart is not recorded as long as the test gauge reading/s are witnessed by theinspector at the start and the end of the test, and if the duration is longer than 30minutes, then at least once every 30 minutes.

3. If the flange rating is 150# or less, the fluid is not a class 2 or 3 hazardous fluidunder, Breaking into Hazardous Pipelines (GM-11-036-02) , then the followingdispensations may be considered:

(a) A standard gauge that has been calibrated within a month of the test may beused in lieu of a NATA certified gauge. The calibration certificate shall beincluded with the test pack in the MDR.





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6.

If parts of a line are not accessible without setting up special access such asscaffolding, then only new, modified or repaired piping, valves and fittings need tobe made accessible for the test for purposes of inspection.

7. If the pressure during a hydrostatic test cannot be maintained due to a pre-existingpassing or leaking valve or fitting, or an inability to fully vent the system, then thetest may be passed by continually pumping up the system to test pressure andinspecting the area of new work for leaks. The Superintendent should perform anassessment of any leaks from existing valves and fittings to see if maintenancerectification work is required. The Superintendent shall arrange for rectification of leaks or passing from new items.

8. Water analysis for water used for hydrostatic tests of austenitic stainless steel linesis not required if CSBP site supplied demineralised water is used.

6.5 SYSTEM DRYING

After hydrostatic testing of the system is complete and approved, all lines and equipment shall becompletely drained of the test fluid. Piping systems vents shall be opened while draining to avoidvacuum. Special attention shall be given to points where water may be trapped, such as in valvebodies or low points.

An air compressor designed to deliver high volume dry air shall be connected to the system highpoint(s). Air shall be blown continuously until all water has been driven out and theSuperintendent accepts the system.

The only exception to this requirement shall be cement-lined pipe, which must be kept in a wetcondition to prevent deterioration of the lining, or if the Superintendent advises that air-drying isunnecessary. An example of when the Superintendent may advise that air-drying is unnecessary iswhen the fluid to flow through the piping is compatible with water, the water is not going to effectany equipment supplied through the piping, and the line is unlikely to suffer from oxygen/watercorrosion between the test and when it is commissioned (e.g. stainless steel lines, very short timeperiod between end of test and commissioning for carbon steel lines).

6.6 CHEMICAL CLEANING OF PIPING SYSTEMS

Chemical cleaning shall not be considered a substitute for line flushing and shall only be performedwhere specified by the Superintendent. Where a piping system is to be chemically cleaned it shallhave previously been flushed, tested and blown dry. Drying may be deferred only if chemicall i i t i di t l f ll h d t t





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Fill system with this solution and circulate for a minimum of eight (8) hours. Sample every hour,test and record for:

Iron (FE++) Concentration : (Ferrous Iron Pick-up parts per million)Acid Concentration : (Percent Weight/Volume)pH : (Using pH meter)

Iron pick-up will depend upon the condition of the pipework but should fall within a range of 600to 2500ppm.

Acid concentration shall not be allowed to fall below 2% weight/volume.

Circulation shall continue until the test results stabilise. Acceptance criteria, for carbon steel pipeis as follows:

Ferrous Iron Pick-up : Minimum 600ppmOptimum 1500ppmMaximum 2500ppm

Acid Concentration : Minimum 2% weight/volumeOptimum 3% weight/volumeMaximum 4% weight/volume

Results of all samples taken shall be recorded and the results filed in the Master Test Pack.

6.7 PNEUMATIC TEST PROCEDURES

Pneumatic testing of piping systems involves the potential hazard of released stored energy incompressed gas and should therefore only be considered when alternative testing procedures cannot be used. Refer to APPENDIX 4 for example authorisation to test through a vessel form.

Any system which has been nominated for pneumatic testing shall be carried out in accordancewith ASME B31.3 with special consideration given to safety during testing including the setting upof exclusion zones (calculated as per Appendix D of AS3788)

Specific procedures will be developed on a project basis relevant to the system being testing, by theContractor in liaison with the Superintendent. The procedure shall require final approval by theSuperintendent before being implemented.

Duplicate, high integrity, pressure gauges shall be fitted to the system under test.





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This test is applicable for ‘extreme toxic danger’ fluid systems.c. Simplified Leak Test.

This is applicable to non-hazardous fluid systems and for hazardous fluid systems with 150# and300# rating. Refer to Section 6.8.8 for details.

The Soap and Bubble Leak test shall be used unless otherwise specified or approved by theSuperintendent.

The systems to be leak tested shall have previously been hydrostatically or pneumatically tested inaccordance with the Code, and therefore all welded joints have been proved sound. The leak test islimited to flanged joints (including vessels), valve glands and instrument connections.

In liaison with the Superintendent, the Contractor shall write a Project specific procedure.

The procedure shall require final approval by the Superintendent before being implemented. The

following guidelines shall apply:

6.8.1 Setting Up

The individual procedure for each leak test shall describe in detail the work required to make thesystem ready. This procedure should be strictly adhered to.

6.8.2 Workmanship

Contractor personnel and operators of plant and equipment shall be competent, experiencedpersons holding current licenses and trade qualifications/certificates commensurate with the work.

6.8.3 Preparation for Testing

All preparatory work associated with the system to be leak-tested, shall be carried out by theSuperintendent’s personnel, including:

a. opening all inline manually operated valves

b. opening all inline actuated valves

c. opening all instrument tapping valves





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A pre test inspection of the system shall be carried out jointly with the Superintendent to ensurethat all preparatory work has been completed, the system is ready to be tested and the testequipment has been set up correctly.

6.8.4 Test Procedure

Purging gas will be:

a. Dry air or nitrogen for Soap and Bubble Test or,

b. Nitrogen/helium mix.

Commence purging system, ensuring that any specified gas mix is within the specified range.During the purging operation the vent valves shall be progressively closed as purging gas isdetected.

Note: If dry air is used, vent valves can be closed prior to purging.

When all vent valves have been closed commence pressuring the system as follows:

a. Increase pressure gradually to an initial pressure of 170kPa(g) and hold for a minimum of ten (10) minutes.

b. Examine all flanged joints, valve glands and other connections where there is a potential forleakage using:

1. A gas spectrometer or other approved method for Nitrogen/Helium Leak Test, or

2. Soapy water or other approved leak testing solution applied to the outside surface of test area.

Should any leaks be observed, the Contractor shall arrange rectification. This may be donewhile the test is in progress with the leak rechecked after at least 15 minutes.

c. Pressure in the system shall be increased to 500kPa and held for five (5) minutes.Thereafter the pressure shall be increased in 500kPa increments to the specified testpressure, with a five (5) minute holding period after each step.

d. When the test pressure has been attained it shall be held for a minimum of one (1) hour oras directed by the Superintendent, during which time the test gauges shall be closelymonitored. Following this hold period the final check for leaks shall be conducted as




p g p g y

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6.8.5 Test Records

The Superintendent shall prepare a ‘Test Pack’ for each system to be tested. Upon successfulcompletion of each test a certificate contained therein shall be signed by the Contractor and by theSuperintendent’s commissioning engineer.

Contractor shall provide pressure gauge calibration certificates for inclusion in the test pack.




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6.8.6 Test Equipment

The Contractor shall supply test equipment. As an example, the minimum for a Nitrogen/HeliumLeak Test is:

a. Bottled nitrogen with standard valve, regulator and pressure indicator,

b. Bottled helium with standard valve, regulator and pressure indicator,

c. Calibrated measuring equipment and associated valves to provide a 2% - 3% (by volume)helium in nitrogen mixture,

d. Pressure gauges,

e. Provision for a chart recorder,

f. Provision for relief valve,

g. Relieving vent with double block and bleed valve,

h. Isolation double block and bleed valves,

i. Portable test bench incorporating test manifold assembly, and

j. Pressure hose(s).

6.8.7 Pressure Gauges

Pressure gauges shall have an operating range, such that the test pressure is between 40% and 75%of the indicated range for each instrument and shall conform to AS 1349 - 1973 (minimum nominal

gauge size - 100mm). The two gauges shall be similar, and test calibrated and certified by a NATAapproved laboratory not more than three months before the date of the test.

Every instrument and gauge shall display an identification label which shall state the date when lasttested and the order of accuracy over the range of the instrument.

Both gauges shall be visible to the operator controlling the test pressure.

6.8.8 Flow Measurement

The devices used to measure gas flow rates shall be calibrated to ensure that the required gasvolumes are maintained.

6.8.9 Simplified Leak test Procedure




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e. A calibrated gauge will be required where the air or nitrogen source could providepressures higher than the piping design pressure. This gauge will be used to monitorpressure to ensure the piping system is not over-pressurised.

f. No flow monitoring is required.

g. Records kept shall be limited to recording which lines were checked and whether therewere any leaks left at the end of the test.

6.9 AIR BLOWING OF PROCESS PIPEWORK

Where air blowing is specified to provide a clean environment for the product at start-up, a Projectspecific procedure shall be written by the Contractor in liaison with the Superintendent, in a formatsimilar to APPENDIX 2. The procedure shall require final approval by the Superintendent beforebeing implemented. The following guidelines shall apply:

6.9.1 Duration of Air Blow

Each system shall be blown against a target plate for a minimum duration of two hours.

6.9.2 Location of Target Plates

Target plates shall be located as specified in the system narrative; however the Contractor shallensure that exiting airflow does not constitute a safety hazard.

6.9.3 Air Flow Requirements

Airflow will be approximately 150% of normal operating velocity. This will be achieved by sizingthe gap at each exit point. (i.e. between the flange and target plate).

6.9.4 Re-instatement

Upon completion of each air blow, Contractor shall reconfigure system as described in theprocedure, and upon final completion, reinstate system in accordance with the drawings and asdirected by the Superintendent.

6.9.5 Compressor

This procedure assumes that the Compressor is an integral component in the process stream and isto be used to provide driving air for the air blowing process. If a temporary unit is brought in toprovide driving air, the company from whom the unit is hired shall provide the pre start-up




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e. Steam supply to turbine from battery limit (also impacted by Steam blowing) if compressorsteam turbine driven,

f. LP Steam supply to seals if compressor steam turbine driven,

g. Cooling Water to any consumers associated with the compressor, and

h. Instrument Air.

Additionally, power shall be available to drive the oil pumps and the compressor motor.

6.9.6 Start-up and Operating Procedures

Prior to starting the compressor for air blowing, all Manufacturers nominated trials shall have beencompleted.

Start up and operation of the compressor shall be in accordance with Manufacturers procedures andshall be carried out by CSBP personnel, under the supervision of the Manufacturer’sCommissioning Engineer.

6.9.7 Control Systems

Control systems for the compressor shall be completed and commissioned such that the compressoris capable of running under manual control for the purposes of air blowing, however, the controlsystem shall be available for the compressor and any flow measuring instruments in the systems tobe blown.

6.9.8 Target Plate Assemblies/Details

Target plates shall resemble a blind flange and shall be capable of being bolted to the pipe or vesselflange. In order to achieve correct blowing velocity the gap between flange and target plate mustbe adjustable. This can be achieved by employing extra long bolts and additional nuts to captureand positively locate the target plate in respect to the flange to which it is bolted.

Target plate shall be painted white.

The Contractor shall provide details of proposed target plate assemblies and number of assemblies/plates required, for the Superintendent’s acceptance prior to manufacture.

Additional materials required for air blowing are listed in each of the air blow procedures.Contractor shall review the procedures and determine actual quantities required to complete airbl i hi h h d l i h d li i f i l




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up. Steam, shall be blown through the piping system via strategically located exit points, movingprogressively through the plant. A Project specific procedure shall be written by the Contractor inliaison with the Superintendent in a format similar to APPENDIX 3. The procedure shall requirefinal approval by the Superintendent before being implemented. The following guidelines shallapply:

6.10.1 Setting Up

The individual procedure for each Steam Blow shall describe in detail the work required to makethe system ready for a blow. This procedure should be strictly adhered to.

6.10.2 Duration of Blow

Each system shall be blown against a target plate until line temperature is as high as possible. Thetarget plate shall then be inspected, and replaced and the system allowed to cool down to 150 ° C.before steam blowing continues. This process shall continue until acceptance criteria are reached.

6.10.3 Acceptance Criteria

Two (2) consecutive blowing operations shall provide values not exceeding:

Copper or Aluminium Target Plates• A maximum indentation of 0.2mm diameter per cm 2, and• five (5) indentations 0.1mm diameter per 20cm 2 .

Stainless Steel Target Plates• A maximum indentation of 0.1mm diameter per cm 2, and• five (5) indentations 0.1mm diameter per 20cm 2 .

6.10.4 Location of Target Plates

Target plates shall be located as specified in the system narrative; however Contractor shall ensurethat exiting steam flow does not constitute a safety hazard.

Steam Flow Requirements

This shall be in accordance with the turbine manufacturer’s recommendations, and would typicallybe sufficient steam to generate a velocity 1 5 times normal operating velocity However the steam




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6.10.6 Target Plate Assemblies/Details

Target plate assemblies shall be constructed such that the plate is easily removable and theassembly shall be capable of being bolted to the pipe or vessel flange at 45 ° to the axis of theflange.

Target plate shall be sized to present an impingement area greater than the flange it is bolted to.

The final blows shall be made against a polished stainless steel, copper or aluminium plate,however initial blow(s) may be made against a painted plate (preferably white).

Contractor shall provide details of proposed target plate assemblies and number of assemblies/plates required, for the Superintendent’s acceptance prior to manufacture.

6.11 SETTING SPRING PIPE SUPPORTS

Pipe Support Index will specify “set”, “cold” and “operating” condition for spring supports.

Supports should be purchased accordingly. In general terms no adjustment to the spring settingshould be required, however the Manufacturers’ installation procedure shall be strictly adhered toand the following checks should be made:

6.11.1 Check Support Range

Check that the support is within the range specified in the pipe support schedule.

6.11.2 Setting of the Support

Adjust the support such that the “shipping tabs” can be easily removed, and following hydrotestand complete reinstatement of the system, remove the shipping tabs.

6.11.3 Check for Cold Set and Line Deformation

With the shipping tabs removed, ensure that the line does not sag or lift, the support does notdeform the structure upon which it is resting and that the spring support has moved to the correct

(cold) position on the scale indicator.

6.11.4 Check Hot Set Position

Check that the support indicator has moved to its operating condition after start-up.



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Version No. 11.0 of 44

Document last modified: 25 February 2011. PDF created: 25 February 2011.

APPENDIX 1 - FLUID SERVICE PIPING SYSTEM INSPECTION CLASSIFICATION FLOW CHART

Note

a. For definition of “Severe Cyclic Conditions” and “Damaging to Human Tissue” refer to ASME B31.3.

b. For individual fluid inspection classes refer to CSBP Engineering Standard Basis for Design - Piping (ES-14-601-01).

c. For details of Inspection Classes refer to Table 1.

d. Welds on Class 150lb and 300lb piping systems, subject to “Severe Cyclic Conditions” (e.g. greater than 7000 cycles for the expected life of the piping system) shall beinspected in accordance with Inspection Class 4, NOT class specified against fluid in CSBP Engineering Standard Basis for Design - Piping (ES-14-601-01).

e. Inner process pipe of jacketed lines to be inspected in accordance with Inspection Class 4. Associated outer pipe to be in accordance with class specified for the jacketingfluid in CSBP Engineering Standard Basis for Design - Piping (ES-14-601-01).

f. When approved by the Superintendent piping systems for “Non Hazardous” fluid service (Category D ASME B31.3) can be subject to an initial service leak test in lieu of hydrostatic testing.

• Non Flammable• Non Toxic• Non Damaging to

Human Tissue• Design Pressure

≤ 1035 kPa• Design Temperature

– 29 to 186 ° C

Non HazardousCategory D

ASME B31.3

Inspection Class7

Hazardous

Inspection Class6

Fluid serviceto be classified

Metallic Piping

System

Piping Class≥ 600

Inspection Class5

SevereCyclic

Conditions

Inspection Class4

ExtremeToxic

DangerHazardous

Inspection Class3

Inspection Class2

• Ammonia• Chlorine• Sodium Cyanide• Nitrous Oxide Gas

• Flammable• Low Level Toxicity• Damaging to Human

Tissue• Design Pressure

> 1035 kPa

• Design Temperature – 29< or >186 ° C

• Non Flammable• Non Toxic• Non Damaging to

Human Tissue• Design Pressure

≤ 1035 kPa• Design temperature

–29 to 186 ° C

Non HazardousCategory D

ASME B31.3

Inspection Class1

N

N

Y

Y

Y

N

Y Y Y

N

Class 150Class 300


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APPENDIX 2 - COMMISSIONING ACTIVITY - AIR BLOW(EXAMPLE)

SCHEDULED ACTIVITY : Air Blow No. 1

IMPACTED TEST PACKS : 312

Description:

Air Blowing of process air lines from the compressor to R 1003. Includes manualcleaning/inspection between the compressor and the expander as shown on P&ID’s 1162-7-9012,9013, 9014, 9015.

Includes Line # From To

600-APR-SBOXWR-1002-70B K1001 E1013

450-APR-SBOXWR-1009-40P Line No 1002 HV3201B300-APR-SB01WR-1010-40P Line No 1002 R1003

20-APR-SBOXWR-1013-30P W1521 Line No 1009

200-APR-SBOXWR-1003-30P Line No 1002 PSV1205

400-APR-SBOXWR-1011-40P Line No 1002 FV3226

350-APR-SBOXWR-1015 K1164 Line No 1009

450-GE-SBOXWR-1096 HV3201A K1002

Procedure:

In normal running mode, the expander requires air to maintain correct operating temperature,therefore the pipework between the compressor and expander cannot be blown against a targetplate and must be carefully inspected and manually cleaned as necessary to ensure that it containsno debris prior to Air Blow # 1.

In Line No 10021. Remove flanged elbow at inlet to E 1013.2. Fit temporary valve W5113 (relocated from cooling water system for duration of Air

Blowing).3. Fit target plate (DN600).




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APPENDIX 3 –COMMISSIONING ACTIVITY - STEAM BLOW(EXAMPLE)

SCHEDULED ACTIVITY : Steam Blow No. 1

IMPACTED TEST PACKS : 364 and Battery Limit Tie-in Pipework

Description:

Steam blowing of MP Steam lines from the Sulphuric Acid Plant to the Ammonia Plant via the ANPlant’s North/South piperack.

Includes Line # From To

150-SM-LB06WW-1241 North/South Battery limit FE422A

Procedure:

g. Isolate and disconnect line at Ammonia Plant and fit target plate.

h. Remove FE422A and fit blind flange.

i. Open battery limit warm-up valves W4246 and W4267.

j. Blow lines in accordance with approved steam blowing procedures from Sulfuric AcidPlant.

Material Requirements:• 1 x DN150 - 600# RF blind flange c/w gaskets & bolts.• Target plate assembly and target plate(s) to suit DN150 pipe.

CSBP will supply steam at 8000 - 10000kg/hr to achieve a minimum.


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APPENDIX 4- AUTHORISATION TO TEST THROUGH A VESSEL(EXAMPLE)

1. TEST PACK INFORMATION

SERVICE : Process Air

TEST PACK No : 311

TEST MEDIUM : Air

SYSTEM TEST PRESSURE : 850 kPa(g)

2. VESSEL INFORMATION

VESSEL No : V 1005

TYPE : Air FilterTEST PRESSURE : 1254 kPa(g)

3. SPECIAL PRECAUTIONS

System fill point shall be upstream of V 1005 and depressuring point shall be downstream.During filling and depressuring, the differential pressure across the vessel filter shall notexceed 10kPa.

4. AUTHORISATION

Authorisation is hereby given to conduct a pneumatic test through this vessel at the systemtest pressure listed in Section 1 above.




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APPENDIX 5 - PIPING TEST PACK INDEX

PIPING TEST PACK INDEX

TEST PACKNUMBER

TESTPRESSURE

ASSOCIATEDEQUIPMENT P&ID REMARKS

ISSUED TOCONTRACTOR

RETURNEDFOR

APPROVAL

PRE-TESTPUNCHLIST

ISSUED

DATETESTED

POST-TESTPUNCHLIST

ISSUED

NUMBER OFPUNCHLIST

ITEMS

NUMBEROF ITEMS

COMPLETE

DATECLEARED

PUNCHLISTITEMS LEFT

OUTSTANDING




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APPENDIX 7 - PIPING FIELD TEST REPORT

PIPING FIELD TEST REPORTService: Priority System No.:

Facility: Piping Test No.:

Test Pack Accepted By:

Plant Location: Test Pressure:

Test Media: CSBP SUPERINTENDENT DATE:

LINE NUMBER ISOMETRICNUMBER P&ID NUMBER FROM TO REMARKS

CSBP AUTHORISATION TO PROCEED WITH PRESSURE TESTING PRESSURE TESTING WITNESSED BY:

PIPING / MECHANICAL ENGINEER NAME DATE FOR CONTRACTOR NAME DATE

FABRICATION INSPECTOR NAME DATE FOR CSBP NAME DATE

Steam Blowing Proceedure

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