G3IR-1000-50-SP-9013_R1

ISSUED FOR CONSTRUCTION

30 May 2012

Client Name : BASF India Limited Project Name : Project GIR Project Number : G3IR

Document No. : G3IR-1000-50-SP-9013 Date 29-MAY-12

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PIPING PRESSURE TESTING

X:\250_PIPING\250E_ENGINEERING_DESIGN_DATA\250E_002_Specs\Master\Piping spec\G3IR-1000-50-SP-9013\Rev1\G3IR-1000-50-SP-9013_R1.DOC

Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No.

Date Description

0 24-APR-12 Issued for Review/RFQ

1 29-May-12 Issued for Construction (IFC)



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DISCLAIMER: THIS SPECIFICATION DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS SPECIFICATION CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.



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Table of Contents

1.0 GENERAL .....................................................................................................................................................5

2.0 PRODUCTS...................................................................................................................................................7

3.0 EXECUTION.................................................................................................................................................8

4.0 ATTACHMENTS....................................................................................................................................... 21



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1.0 GENERAL

1.1 Summary

A. Scope of Specification

This specification prescribes the methods, tasks, scope, and criteria for pressure testing spool pieces and installed piping systems. Any deviation from this specification requires written approval from Owner or his representative.

Testing of IBR Piping shall be as per Indian Boiler Code, 1950, Regulation-374.

B. Work Not Included

The following are excluded from the requirements of this specification:

1. Any package unit previously tested by the manufacturer in accordance with the applicable codes.

2. Instrument piping lead lines between the root valve at the process or utility line and the connected instrument and control piping used to connect air or hydraulically operated control apparatus.

3. Atmospheric sewers and drains.

4. Plumbing systems, which are tested in accordance with the applicable plumbing codes.

5. Lines and systems open to the atmosphere.

6. Non-metallic systems, which shall be tested per manufacturer’s recommendation.

C. Terminology

1. Design Pressure: The maximum pressure a piping system will see during normal operation, as defined by ASME B31.3. This pressure is listed in the line list.

2. Test Pressure: The pressure required to perform a pressure test, as defined by ASME B31.3. This pressure is listed in the line list.

3. Piping system: The process or utility piping labeled with a line number on the PID’s with the same Line Class Identifier, Fluid Code, Pipe Class and process conditions.

4. Category D Fluid Service (ASME B31.3): Owner’s designation for a fluid service in which all the following apply:



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a. The fluid handled is nonflammable, nontoxic, and not damaging to the human tissues.

b. The design gage pressure does not exceed 10.35 barg.

c. The design temperature is between minus 20 degrees F (-29 degrees C) through 366 degrees F (186 degrees C).

5. Test Pressure: The test pressure as listed in the line list.

6. Test system: A system containing several Piping systems with identical or different process design conditions, which may and can be Pressure tested together because the required test conditions are identical or within required limits

7. Test Temperature: The minimum temperature occurring during the test period of either the metal temperature of the piping being tested (including any vessels or equipment included in the test) or the test fluid temperature.

8. System Test: The testing of a Test system as defined in 1.1.C 6 above, using a single test procedure and pressure.

1.2 References

The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for construction unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, work included in this specification shall conform to the applicable provisions of these publications.

A. API (American Petroleum Institute)

• API 600 Steel Gate Valves - Flanged and Butt-Welding Ends • API 602 Compact Steel Gate Valves • API 609 Butterfly Valves • API-6D Ball Valves B. ASME (American Society of Mechanical Engineers)

• ASME B16.5 Pipe Flanges and Flanged Fittings • ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges • ASME B16.34 Valves - Flanged, Threaded, and Welded End • ASME B31.3 Process Piping

C. ASTM (American Society for Testing and Materials)

• ASTM A36 Specification for Structural Steel



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D. ASME Boiler and Pressure Vessel Code.

• Section V Nondestructive Examination

E. MSS standards (Manufacturés Standardisation Society)

• MSS-SP-88 Diaphragm Valve

1.3 Pressure Testing

A. The pressure test shall be performed after the NDE and before the internal cleaning of the pipe.

B. Test pressure for each line shall be specified in the Piping Line List. Additional data, as listed below, shall be provided by Home office Engineer.

• Equipment test pressures

• Test pressures of special piping components such as valves, strainers, steam traps, etc. During testing, all valves shall be in open condition and must not be used as test limit. Contractor to check that valve seat pressure is greater than the system test pressure. Strainers can be included in testing loop with or without mesh. . All these details regarding test pressures for individual piping components or Equipments shall be provided to successful bidder.

• Special testing instructions and cautionary notes

2.0 PRODUCTS

2.1 Temporary Welded End Closures

A. The use of plate for temporary welded on end closures is not allowed.

B. Materials used for welded on end closures such as caps or blinded flanges must be per project approved piping material (line class) specifications. Project approved welding procedures and welding requirements must be adhered to. Exceptions or deviations to the approved specifications must be approved by the home office engineer.

2.2 Temporary Non Welded End Closures

When required, non welded temporary end closures, such as test plugs, must be selected and used per manufacturer’s recommendations and requirements.



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2.3 Temporary spool pieces

Where in-line instruments or valves have to be removed during the test, temporary spool pieces may have to be provided with temporary gaskets and bolting. Spool pieces shall be able to withstand the intended test pressure and be fabricated of material per approved piping material specifications.

2.4 Pressure Test Blinds

A. Plain test blanks with 1.5 mm flat non-asbestos full face or ring type gaskets shall be used for blanking flat face, raised face, male and female, and tongue and groove type flanges. Provide full face blanks and gaskets at 125# CI connections. However, where permanent operational blinds are installed, they may be used for field pressure testing.

B. A field procedure must be established and care taken to ensure the installation and removal of material specified for testing. The following is one method for identifying test material:

Plate material, extra length bolts, and gaskets for testing shall be furnished by the field unless dictated otherwise by contract requirements. The outer periphery (edge) of each test gasket shall be dabbed with a spot of fluorescent yellow paint in 4 spots (90 degree equidistant) prior to installation. End points of studs and heads of bolts shall be dabbed with a spot of fluorescent yellow paint. Refer to Attachment 03 for maximum test pressures at various blank thicknesses.

2.5 Solutions

A. Corrosion Inhibitor

A suitable non-toxic rust inhibitor for hydrotesting of clean lines, and / or harden inhibitor in lines with stainless steel components.

B. Soap Solution

A suitable soap solution for determining leaks during the pneumatic testing of systems.

3.0 EXECUTION

3.1 Preparation

A. General

1. The entire facility shall be checked against the latest P & Id’s and other design specifications / codes



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2. Prior to operation, installed piping shall be pressure tested except where otherwise qualified in section 1.1B, of this specification. The test type and pressure shall be as indicated on the piping line list.

3. The test shall be hydrostatic using water unless 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 may be used. Testing of ferritic piping, however, is limited to the temperature restrictions in Section 3.5E, of this specification.

a. If a flammable liquid is used, its flash point shall be no less than 49 degrees C and consideration shall be given to the test environment.

b. If testing with glycol water mixtures to prevent freezing, the disposal problem of the test fluid shall be considered.

4. The following systems may be tested pneumatically (with authorization from the Owner of the installation).

a. The weight of the hydrotest liquid would overstress supporting structures or pipe wall in a gas, steam, or vapor lines.

b. Lined pipe that could be damaged by the hydrotest liquid.

c. The instrument air headers shall be tested with dry air. A commodity test as described in Section 3.3.D of this specification is be used if it is Category D Fluid Service, the system is complete and the instrument air compressor is operational.

d. The process or piping material would be adversely affected by water.

5. In circumstances when neither hydrostatic nor pneumatic tests are considered practical, an alternative test per section Error! Reference source not found. may be employed, subject to Owner and Construction Authorization and if all of the following applies:

a. A hydrostatic test would do the following:

(1) Damage linings or internal insulation.

(2) Contaminate a process which would be hazardous, corrosive, or inoperative in the presence of moisture.

(3) Present a danger of brittle fracture from low metal temperature during test.

b. A pneumatic test would do the following:

(1) Introduce considerable hazard due to possible release of stored energy in the system



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(2) Present a danger of brittle fracture from low metal temperature during test.

6. For aboveground Fluid Category D piping an Initial Service Leak Test (Commodity Test) may be performed if approved by the Owner. See also section 3.3D.

B. Vessels and Equipment

1. The following shall be excluded from hydrostatic tests:

a. Vessels or equipment supported by other vessels or equipment or by a support structure or foundation, not capable of supporting the hydrostatic test load.

b. Vessels or equipment not capable of sustaining the hydrotest load, and those with internals or linings that would be damaged by the test fluid.

2. The following shall be excluded from all pressure tests:

a. Pumps, compressors, and turbines.

b. Equipment and vendor furnished piping specifically recommended by the manufacturer not to be tested.

3. The pressure on any point in vessels or equipment included in the pressure test shall not be greater than the shop test pressure for that equipment as stated on the vendor's equipment drawing or specification sheets. In the event the piping test pressure is greater than the vessel or equipment test pressure, the piping shall be disconnected, blinded, and tested separately. If the piping cannot be disconnected (welded connection), one of the following shall be implemented:

a. Home office Engineer shall request written approval from the vendor to test at the required piping test pressure as indicated in the piping line list.

b. Reduce piping test pressure as necessary after review and approval of the owner. Refer to Section 3.3A.2.

4. Certain types of exchangers are specifically designed for a low allowable differential pressure between shell and tubes, as stated on the vendor drawings and specification sheets. These should be checked; and if necessary, test both shell and tubes simultaneously as one system with the same pressure or exclude both sides from the test.

5. Pressure vessels with two or more pressure chambers are specifically designed for a low allowable differential pressure between pressure chambers as stated on the manufacturers' drawings. These should be checked; and if necessary, test all



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adjacent pressure chambers simultaneously as one system with the same pressure or exclude all pressure chambers from the test.

C. Instruments

1. All instruments shall be protected from damage when hydrotesting process and utility piping systems. Attachment 02 outlines the status of instruments during testing to insure protection.

2. Instruments not listed in Attachment 02 shall not be subjected to the pressure test unless authorization is obtained from the Owner.

3.2 Test Medium Criteria

A. Care shall be taken to ensure the use of clean water for these tests. A suitable filter should be provided in the filling line, should foreign matter such as sand, rust, or other particles be in evidence in the proposed test water. The use of seawater is prohibited.

B. Non-hygienic piping shall use water that meets the Local Public Health Drink Water Standard for these tests. A 30 mesh filter should be provided in the filling line to prevent foreign particles in the test water. The use of sea water is prohibited. Hygienic tubing shall use deionized water with a chloride concentration less than 25 ppm.

C. Water used for hydrostatic testing of austenitic stainless steel piping, vessels, and equipment including those with austenitic stainless steel claddings, linings, or internals shall conform to the requirements listed below. These requirements also apply to claddings or linings that are welded with austenitic stainless steel weld filler and to medium and high nickel alloys and ferritic chromium stainless steel where pitting corrosion is a risk.

1. Water containing more than 50 ppm (Parts Per Million) chlorides shall not be used.

2. Water containing fewer than 50 ppm chloride does not require chloride inhibitor treatment.

3. Water containing more than 50 ppm (parts per million) chlorides shall not be used for non-hygienic piping. Hygienic tubing shall use deionized water with a chloride concentration less than 25 ppm.

4. Piping, vessels and equipment must be drained thoroughly after testing. Where complete drainage is impossible, the system shall be flushed free from all test water using demineralized water containing fewer than 5 ppm chlorides, alcohol, petroleum distillate, or another suitable flushing solution authorized by Fluor and the Owner. Hot air drying is not acceptable in lieu of flushing, but water may be blown out of pockets using air.



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5. Risk of pitting corrosion is considerably diminished if the time between pressure testing and startup is as short as possible. Hence contractor will ensure that startup is done at the earliest after pressure testing.

D. Piping that has been internally cleaned by sandblasting shall be tested after installation using a water solution containing a suitable corrosion inhibitor. After piping has been tested, it shall be drained and blown dry with air or nitrogen. A suitable corrosion inhibitor not objectionable to process commodity shall be used.

E. Piping that is to be chemically cleaned after installation shall be tested and all repairs made prior to cleaning.

F. Systems that are pneumatically tested shall meet the following test criteria:

1. Testing shall be performed using filtered, non lubricated dry air only. Air provided directly from the plant compressor shall not be acceptable. Bottled dry compressed air or dry nitrogen may be used as an alternative and shall be arranged and supplied by the contractors at his own cost.

Note!!! Under no circumstances shall water be used in pressure testing of the system.

2. Uni-directional valves that are supplied with vent holes should be tested so the vent hole shall be located toward the upstream (high pressure) end when the plug is in the closed position.

3. After final test, all valves shall be wiped clean once more with clean, lint free rags and trichloromethane solvent. This cleaning shall include all accessible surfaces. Do not submerge the valve in the solvent. No trace of trichloromethane must remain or be trapped inside the valve.

3.3 Test Methods and Pressures for ASME B 31.3 Piping systems

A. Hydrostatic Testing of Piping Designed for Internal Pressure shall be in accordance with ASME B31.3, section 345.

1. The calculated test pressure for each line shall be as specified in the piping line list.

2. If the design conditions of piping attached to a vessel are the same as those of the vessel, the piping and vessel may be tested together at the test pressure of the vessel. However, if the piping may be subject to higher design conditions; if it requires a higher test than the connected equipment; or if the piping is designed for lesser operating conditions than the connected equipment and could be overstressed by a system test, it shall be isolated and tested separately.

3. Where the test pressure of the piping exceeds the vessel test pressure and it is not considered practical to isolate the piping from the vessel, the piping and the vessel may be tested together at the vessel test pressure, provided the Owner approves and the vessel test pressure is not less than 77 percent of the piping test pressure calculated in accordance with ASME B31.3, section 345.4.2.



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B. Hydrostatic Testing of Piping Designed for External Pressure

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 no less than a gage pressure of 15 psig.

2. In jacketed lines, the internal line shall be pressure tested on the basis of the internal or external design pressure, whichever is more critical. This test must be performed before completion of the jacket to provide visual access to the joints of the internal line.

3. The jacket shall be pressure tested on the basis of the jacket design pressure. Care must be taken to prevent damage to the internal line when testing the jacket.

C. Pneumatic Testing

If the piping is tested pneumatically, the test pressure shall be 110 percent of the design pressure. Pneumatic testing involves the hazard of released energy stored in compressed gas. Particular care must be taken to minimize the chance of brittle failure during pneumatic test. The test procedure shall be in accordance with section 3.6 of this specification. Pneumatic test shall not be carried out without owner approval for piping systems which cannot tolerate water during operation or where pipe supports cannot take full of water load.

D. Initial Service Leak Test for Category D Fluid Service Only (ASME B31.3)

1. A piping system used only for Category D Fluid Service, not previously hydrostatic or pneumatic tested in accordance with this specification, may be tested at the normal operation conditions of the system during or prior to initial operation by examining for leaks at every joint. Commodity testing shall require Owner's authorization.

2. A preliminary check shall be made at no more than 25 psig pressure when the contained fluid is a gas or vapor. The pressure shall be increased gradually in steps providing sufficient time to allow the piping to equalize strains and to check leaks.

E. Tightness Test-

Except for piping systems identified as Category M Fluid Service, piping systems designed for internal gage pressures at or above 0 but less than 1.02 bar g shall be tested for tightness in accordance with one of the following methods:

a. Hydrostatic

Fill with water to highest point in system and check all joints for leakage.



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b. Pneumatic

Pressurize system to 0.34 barg with air or other nonflammable gas and check all joints for leakage using a bubble forming solution.

The fluid handled shall be nontoxic and not damaging to human tissue and have a design temperature within the range of minus 20 degrees F to 366 degrees F, inclusive

F. Vacuum Services

` Lines in vacuum services shall be tested at a minimum internal pressure of 1.5 kg/cm2 unless limited to a lower value by design. Where it is not possible to test hydrostatically, the pipe lines shall be tested pneumatically at 1 kg/cm2

3.4 Test Preparation – Field Procedures

A. Joints, including welds, shall be left non insulated and exposed for examination during the test, except that joints previously tested in accordance with this specification may be insulated or covered. If a sensitive leak test is required, joints mentioned above shall also be left unprimed and unpainted.

B. Underground portions of piping systems may be tested and covered before testing aboveground portions.

C. 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/package.

D. Lines that are counterweight supported shall be temporarily blocked during testing in order to sustain the weight of the test fluid. Spring hangers that 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.

E. Before testing, the following procedures shall be carried out:

1. Verify that any required heat treatment has been performed.

2. Piping systems shall have been completely checked (punched out).

3. Lines, vessels, and equipment shall be checked to ensure that the entire system can be completely drained after testing.

4. Vents or other high point connections shall be opened to eliminate air from lines that are to receive a hydrostatic test.

5. System shall be purged of air before hydrostatic test pressure is applied.

6. All Instruments are removed from service per Attachment 02.



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F. Field personnel shall review all vessels and internals in order to determine best method to prevent air entrapment when filling and to prevent vacuum when draining.

G. Short pieces of piping that must be removed to permit installation of a blind or blank shall be tested separately.

H. Flanged joints, at which a blank is inserted to isolate other equipment during a pressure test, shall be in service tested after the blank is removed. The in service test shall be conducted prior to the addition of insulation.

I. 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 up the check valve closure mechanism or remove check valve completely, and provide necessary filler piece or blinds.

J. Systems that include expansion joints shall be investigated to see that any required temporary restraints, anchors, or guides are installed or removed prior to test.

K. 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 test pressure.

L. Piping or sections of piping to be tested may be isolated by closed valves provided the valve closure is suitable for the test pressure.

M. Where it is possible, systems or sections shall be tested at a flanged isolation using a blind flange or hydrostatic test blind. For required thickness of Test Blanks see Attachment 03.

N. Where a suitable flanged isolation is not available, vessels, equipment, or other piping not included in the system pressure test shall be either disconnected from the system or isolated by blinds or other means during the test.

O. Valves shall be open, but not back-seated. Although not recommended, Piping, or sections of piping, to be tested may be isolated by closed valves in exceptional cases and only provided the valve closure is suitable for the test pressure.

P. Unidirectional valves that are supplied with vent holes should be tested so the vent hole shall be located toward the upstream (high pressure) end when the plug is in the closed position.

Q. All components which might be damaged by the test pressure, such as traps, instruments, diaphragm valves, relief valves, pumps, vessels, etc, shall be blanked or removed from the Piping systems. For welded-in control valves their internals have to be removed and stored carefully. Valves and other in-line piping components for which the operating temperature is below 0 degrees C shall be removed prior to hydrostatic test, unless drying out can be properly achieved. Test pumps shall be disconnected from the test system prior to line inspection. All piping shall be thoroughly cleaned by flushing with water, or by blowing out with



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air or steam, if pneumatically tested. It shall be verified if all lines, vessels and equipment can be completely drained after testing.

R. Vessels, heat exchangers and equipment, which have to be excluded from pressure testing, shall be physically disconnected and, unless otherwise stated, flushing with water shall not be done through these items. If there is a need to pressure test through equipment with two or more pressure chambers (e.g. welded-in heat exchanger) special care is required for allowable differential pressure between pressure chambers as stated on the Manufacturers' drawings. If necessary, test all adjacent pressure chambers simultaneously as one system with the same pressure or exclude all pressure chambers from the test. This applies also for de-pressurizing the system after test completion. For these specific pressure tests a field procedure shall be prepared and is subject to approval by Construction.

S. In cases where a pipe line being tested extends beyond the battery limit without flanges, it shall be tested to the first block valve or set of flanges outside the battery limit. Care shall be taken to see that lines beyond limits are tested in accordance with pressure specified on Offsite Field Pressure Test Flow Diagrams.

T. Piping which connects to, or is continuous with, piping installed by others shall be isolated from these lines by pipe test blanks or blinds during pressure testing and flushing. Where it is necessary to include portions of such lines in the test, testing shall be performed up to the first possible blinds and test blanks in the system provided by others.

U. The normal locations for the pressure test gage are at grade near the pressure test pump. Readings may be made at higher points providing the gage pressure reading and the static head (0.433 psi/ft) between grade and the point of measurement do not exceed the maximum test pressure. Gages shall be tagged with the date last calibrated, and this activity shall be recorded.

V. In order to hydrostatic test as much piping as possible at one time, a systems test may be employed. This test shall include one or more lines and, if possible, connected to vessels and equipment. Pressure test P&ID’s shall be developed for identifying test packages. Test packages shall be by Test Systems / circuits.



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3.5 Hydrostatic Test Procedure

A. The minimum test pressure for a system test is as listed in the Piping Line List.

B. The maximum system test pressure shall not exceed the pressure test rating of any piping component, or the shop test pressure of any vessels or equipment included in the test system. Maximum test pressures for flanges and valves conforming to ASME B16.5 and ASME B16.34 are given in Attachment 1.

C. Systems or sections of systems to be tested may be isolated by closed valves. provided the valve body and seat are suitable for the test pressure. Do not use closed diaphragm valves for isolation.

D. Where a suitable valve is not available, vessels, equipment, or other piping not included in the system pressure test shall either be disconnected from the system or isolted by blinds or other means during the test.

E. Hydrostatic test pressure shall not be applied until the vessel or equipment and its contents are at approximately the same temperature. To minimize the risk of brittle fracture, pressure tests through vessels and equipment shall not be conducted when the test liquid or metal temperature is below 16°C. Pressure tests in ferritic piping systems that do not include vessels or equipment may be conducted below 16°C but shall not be conducted when the test liquid or metal temperature is below 5°C.

F. Hydrostatic test pressure shall be maintained for a sufficient length of time to visually determine whether there are any leaks, but not less than 10 minutes. Contractor shall not be required to maintain the test pressure in excess of 2 hours after notification of the Owner's authorized inspector.

3.6 Pneumatic Test Procedure

A. Minimum Metal Temperature

At time of testing, the minimum pipe metal temperature shall be as listed below:

Minimum Temperature Nominal Wall Thickness

60 degrees F (16 degrees C) Carbon steel 40 NB and less

60 degrees F (16 degrees C) Post heat treated ferritic 25 NB and less

40 degrees F (5 degrees C) Austenitic steels 25 NB and less

Note: Minimum temperatures for materials not listed above shall be determined by Piping Engineering when required by field construction.



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B. Clear the test area before bringing the line up to test pressure. It may be desirable to conduct pneumatic tests during weekends or when fewer personnel are present. In any event, the site safety engineer shall take whatever precautions are deemed necessary to protect workers during such tests.

C. A pressure relief device shall be provided, having a set pressure not higher than the test pressure plus the lesser of 50 psig or 10 percent of the test pressure.

D. When pneumatic testing at over 15 psig, a preliminary check at 15 psig shall be made to locate major leaks. The pressure shall be increased in gradual steps of 5 psig or 10 percent of the test pressure, whichever is greater.

E. A double block and bleed valve arrangement shall be included in the pressurizing line to the system being tested. A test pressure gage shall be downstream of the double block. After each pressure step has been reached, close the block valve and open the bleeder to atmosphere. If after a 5 minute period, the step pressure is held, proceed to the next step pressure; if not, examine the entire system for leakage.

F. When the system has been brought up to the test pressure shown on the piping pressure test system record, the pressure shall then be reduced to the design pressure before examining for leakage. All joints and welds shall be covered with soap solution in order to detect any leakage. Soap shall be a commercial preparation made specifically for leak detection. Soap solutions are to be low chloride and designed specifically for use in pneumatic testing of stainless steel systems.

G. Before soaping the joints, the entire line should be walked to determine whether there is any audible evidence of leakage. Any leaks found at the time shall be marked and repaired after first depressurizing the line.

H. Bolting shall not be tightened while systems being tested are pressured above 30 psig.

I. Pneumatic test pressure shall be maintained for a sufficient length of time to permit thorough visual inspection of all joint and weld seams but not less than 10 minutes. Contractor shall not be required to maintain test pressure in excess of 2 hours after notification of Owner's authorized inspector. Pressure shall be reduced gradually when depressurizing.

3.7 Tightness test Procedure

For tightness testing the system shall be filled with water or pressurized with air or other nonflammable gas and then all joints are to be checked for leaks. When testing with air or gas the joints shall be checked using a bubble forming solution.

3.8 Initial Service Leak Test Procedure

For the Initial Service Leak Test the test pressure shall be applied in increments of approx. 20% allowing time between increments for the piping system to equalize



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strains and to observe the leaks. However, for compressed gas systems the initial increment shall not exceed 170 kPag. Application of the test fluid to the piping system shall be through a valve opened slightly to minimize damage in the event of a piping failure. The pressure shall be maintained for sufficient time to determine if there are any leaks but not less than 10 minutes. Release pressure, repair any leaks, and retest Underground pipe joints shall be exposed for a distance of two feet on each side of joints and shall not be backfilled until piping has been tested and approved.

3.9 Test Records

A. Records shall be made of each piping system test utilizing a form entitled Piping Pressure Test System Record, (Attachment 04). Forms, when completed, shall be retained in the Field QC file as a permanent record. These records shall include the following information:

• Date of test • Identification of piping system and any vessels or equipment tested with the

piping system • Test medium • Test pressure • Minimum ambient temperature • Test medium temperature • Certification by examiner • Test results • Name of test operator • Minimum metal temperature (if applicable)

B. Upon Completion of the piping installation, the only retained records shall be a letter of certification by owner's authorized inspector that all piping has been pressure tested as required by these procedures.

3.10 Test Completion

A. Pressure tests are successful if no leaks, no cracks and no deformations are detected. If leaks are found, their location shall be marked the pressure shall be gradually released, and the piping shall be drained or vented. All vents have to be opened and kept open in order that no vacuum is generated. Huge amounts of water have to be drained directly to sewer inlet (e.g. by hose) in order not to flood ground.

B. If leaks are found, appropriate repair or replacement shall be made. The affected piping shall be re-tested at the pressures originally specified for the test. Re-testing of minor repairs or additions may be waived, provided approval of Owner is obtained and the welding is nondestructively examined according to Section 3.4.A.2, of this specification.

C. After completion of testing the system shall be cleaned / flushed, all temporary blanks and blinds shall be removed, all operating blinds returned to proper position, and all lines and piping components (except those tested according to Section 3.4B., of this specification) shall be completely drained. Valves, orifice plates, expansion joints, and short pieces of piping that have been removed shall be



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reinstalled with proper new gaskets in place. Valves that were closed during hydrotest shall be opened to ensure drainage of the bonnet cavity. Lines being drained after testing and cleaning shall have all vents open. Piping systems downstream of check valves should be inspected to ensure complete drainage. Piping containing soft-seat valves shall be flushed and drained before the valves are installed.

D. Direct connected transmitters at orifice flanges must be disconnected when replacing orifice plates to avoid distorting the connections.

E. Care shall be exercised in controlling the rate of drainage from vessels with respect to the inflow of air through the vent to ensure that the vessel is not subjected to vacuum. After vessels have been completely drained, vents, cyclones, and other internal closures that were opened before testing shall be closed.

F. After lines have been drained, temporary supports shall be removed, and insulation and painting completed. Spring hangers provided with stops to carry the test load shall have these stops removed.

G. Flanged joints at which test blinds have been removed shall not be retested.

H. General

1. Instruments which were removed or blocked out for test shall be reinstalled and blocks placed in the normal operating position.

2. Bolting and gaskets used for pressure testing shall be removed and replaced with bolts and gaskets specified in the Line Class.

3. Check valves that were jacked open or the internals were removed for pressure testing shall be returned to their proper operating position.

4. Vessel and equipment internal closures which were opened specifically for pressure testing shall be closed.

5. Instruments and process lead lines that were subjected to the hydrostatic pressure test shall be blown out with dry air or nitrogen.

6. Vent and drain connections that were added solely for pressure testing shall be closed and seal welded as required. Drains shall have either the valve closed and plugged or, if the valve is removed, the connection plugged and seal welded as required.

7. Painting and insulation shall be completed after inspection of seal welded vents & drains.

8. Strainer screens shall be removed, cleaned, and reinstalled.



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4.0 ATTACHMENTS

Attachment 01 Maximum Hydrostatic Test Pressure (bar g) for Flanges and Valves.

Attachment 02 Status of Instruments during Pressure Test.

Attachment 03 Schedule of Maximum Allowable Hydrostatic Test Pressures (bar g) for the Listed Test Blind Thicknesses.

Attachment 04 Pressure Test System Record.



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ATTACHMENT – 01

Maximum Hydrostatic Test Pressure (bar g) for Flanges and Valves

Material

Carbon Steel

Carbon Moly

CR - Moly Stainless Steel

Normal (1.1) C-1/2 (1.5) 1/2-1/2 1, 1-1/4-1/2(1.9) 2-1/4-1(1.10) 5-1/2(1.13) 9-1(1.14)

304(2.1) 316(2.2) 321(2.4) 347.348(2.5)

304L, 316L(2.3) 309(2.6) 310(2.7)

AS

ME

B16

.5

Fla

nge

Cla

ss

Shell Seat Shell Seat Shell Seat Shell Seat Shell Seat Shell Seat

150 31.0 19.7 27.6 18.3 31.0 20.0 29.3 19.0 24.1 15.9 27.6 17.9

300 77.6 51.0 72.4 47.9 77.6 51.7 75.8 49.6 62.1 41.4 70.7 46.2

400 103.4 68.3 96.5 63.8 103.4 68.9 100.0 66.2 82.7 55.2 93.1 61.7

600 153.4 102.0 144.8 95.8 155.1 103.4 150.0 99.3 124.1 82.7 139.6 92.7

900 231.0 153.1 217.2 143.7 232.7 155.1 224.1 148.9 186.2 124.1 208.6 138.9

1500 384.4 255.5 360.2 239.2 387.8 258.6 372.3 248.2 310.3 206.8 348.2 231.7

2500 639.5 425.4 599.8 398.9 646.4 430.9 620.5 413.4 517.1 344.7 579.2 386.1

NOTES:

1. The above chart is based on ASME B16.5, and provides the maximum allowable hydrotest pressures of DN 15 through DN 600 flanges (shell test) and flanged and standard class weld end valves (shell test, with valve open and seat test, with valve closed). Seat test is based on ASME B16.34, Para. 2.5.3.

2. Flanged valves manufactured according to API-600 and API-602 may be tested in accordance with the above chart. Carbon steel, Normal (1.1), 800# screwed or socket weld valves manufactured according to API-602 and API-606 may be tested to 206.8 bar (shell test) or 136.2 bar (seat test).

3. For valves not conforming to the above standards or ASME B16.5, the manufacturers' recommended test pressure limits for both shell and seat shall be used.

4. Maximum test pressures for flanges and valves over DN 600 and piping components not covered by this chart shall be provided by Home office Engineer.(To the Successful bidder)

5. The maximum test pressure for pneumatic testing shall not exceed 75 percent of the stated values.



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ATTACHMENT – 02

Status of Instruments during Pressure Test

Block and Vent

Remove for Test

Blank Off

Include in Test

Notes

1. Analyzer Flow Cells X

2. Control Valves - except regulators and pressure balanced X

3. Control Valves - pressure balanced X

4. Flow Instruments - D/P cell and bellows types X

5. Flow Instruments - rotameters and mag. flow types & mass flow X

6. Flow Meters - positive displacement, mass flow turbine and vortex types X

7. Flow Indicating Switches - bellows type X

8. Flow Switches - vane type X

9. Gage Glasses X

10. Level Instruments - displacer type X 1

11. Level Instrument - D/P cell and bellows types X

12. Level Switches - float type X 1

13. Orifice Plates/Restriction Plates X 2

14. Pressure Gages X

15. Pressure Instruments - all types X

16. Pressure Regulators X

17. Pressure Switches X

18. PSEs X

19. PSVs X 3,4

20. PSVs, TSVs - 3/4" and 1" Screwed X

21. Temperature Gages X

22. Temperature RTDs X

23. Thermowells X

NOTES:

1. Caution - do not overpressure float or displacer. If in doubt, do not test; block and drain instead. 2. Install after hydrotesting and line flushing. 3. Test gage may be used if one is furnished. 4. Blinds not required on PSV outlets discharging into a system being tested at 1.0 bar g or less. 5. All instruments shall be protected from damage due to freezing. In preparation for cold weather and during

cold weather all instruments must be drained and process lead lines blown out with air or nitrogen.



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ATTACHMENT – 03

Schedule of Maximum Allowable Hydrostatic Test Pressures (bar g) for the Listed Test Blind Thicknesses

Nominal Pipe Size

Plate Thk

50 80 100 150 200 250 300 350 400 450 500 600

7 mm 138.8 64.2 38.8 17.9 10.5 6.8 4.8 4.0 3.1 2.4 2.0 1.4

10 mm 312.2 144.4 87.4 40.3 23.8 15.3 10.9 9.0 6.9 5.4 4.4 3.1

14 mm 555.0 256.6 155.3 71.8 42.3 27.2 19.4 16.0 12.3 9.7 7.9 5.4

16 mm 867.3 401.0 242.6 112.1 66.1 42.5 30.2 25.1 19.2 15.2 12.3 8.5

20 mm 577.5 349.4 161.4 95.2 61.2 43.5 36.1 27.6 21.9 17.7 12.3

24 mm 475.5 219.7 129.6 83.3 59.2 49.2 37.6 29.7 24.0 16.7

26 mm 621.0 287.0 169.3 108.8 77.4 64.2 49.2 38.8 31.4 21.9

30 mm 363.2 214.2 137.8 97.9 81.2 62.2 49.2 39.8 27.6

32 mm 448.4 264.5 170.0 120.9 100.2 76.7 60.7 49.2 34.1

36 mm 542.5 320.0 205.7 146.2 121.3 92.8 73.4 59.4 41.3

40 mm 645.7 380.8 244.8 174.1 144.4 110.5 87.4 70.7 49.2

42 mm 446.9 287.4 204.3 169.4 129.7 102.5 83.0 57.6

46 mm 518.3 333.3 236.9 196.5 150.4 118.9 96.3 66.9

48 mm 595.0 382.6 272.0 225.6 172.7 136.4 110.5 76.7

52 mm 677.0 435.3 309.4 256.6 196.5 155.3 125.8 87.4

NOTES:

1. The Tabulated Pressures above are based on the formula stated in ASME B31.1, Para. 104.5.3 (b) using:

a. Flat non-asbestos gaskets conforming to ASME B16.21. b. Structural grade carbon steel plate, ASTM A36 having a minimum specified yield strength of

2482 bar.

2. For plate that is identified as having a lower minimum yield strength, the allowable hydrostatic pressure must be reduced in accordance with the following formula:

Pma = Yx / Y where: Pma = Maximum Allowable Test Pressure Y = Minimum Specified Yield Strength, ASTM A36 Yx = Minimum Specified Yield Strength for Material Selected

Pneumatic Test Pressures shall not exceed 50 percent of the values indicated.



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ATTACHMENT – 04

PRESSURE TEST SYSTEM RECORD

SECTION I CWP No. _____________ REV.: SYSTEM TO BE TESTED: ________________ UNIT: _______________ TEST LOOP No. ________________ TEST BOUNDARY: ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ DESIGN PRESS: __________ BARG DESIGN TEMPERATURE: __________ DEG C TEST PRESSURE: __________ BARG ALLOWABLE PRES. DROP __________ BAR TEST MEDIUM: __________ NOTE: SECTION I COMPLETED BY: ____________________________ PRE-TEST VERIFICATION OF READINESS BY: __________________________

SECTION II TEST DATE: ______________ AMBIENT TEMP.: ________________ TEST TIME: ______________ START ___________ FINISH GAGE PRESSURE: SOURCE: ______________ START ___________ FINISH REMOTE: ______________ START ___________ FINISH SERIAL NUMBERS: SOURCE GAGE: ____________ REMOTE GAGE: __________ REMARKS: ________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ TEST ACCEPTED: ( ) YES ( ) NO IF NO, WHY? ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ INSPECTOR: __________________________________ DATE: ______________ DISTRIBUTION: (ORIGINAL) OWNER'S INSPECTORS (FILE) __________ (COPY) FLUOR ENGINEER __________ (COPY) REQUESTOR __________



Page 26 of 26



ISOLATION POINTS NOTE: A COPY OF THIS BLINDING LIST TO BE KEPT IN THE SHIFT FOREMAN'S OFFICE. JOB DESCRIPTION: __________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ BOUNDARY OF HYDROTEST: _________________________________________________________________________ ____________________________________________________________________________________________________ ENGINEERING JOB NUMBER: ________________ WORK ORDER NUMBER: ____________________ OPERATIONS _______________________________________________________________________________________ ____________________________________________________________________________________________________ FOREMAN APPROVAL TO INSTALL BLINDS: NAME: ___________________________________ DATE: _____________ FOREMAN VERIFICATION BLINDS ARE REMOVED: NAME: ___________________________________ DATE: _____________ ---------- BLINDS ---------- ITEM BLIND SIZE PRESSURE TAG REMOVAL NUMBER LOCATION NUMBER VERIFIED 1 ______________________________ _________ ___________ ___________ _______________________ 2 ______________________________ _________ ___________ ___________ _______________________ 3 ______________________________ _________ ___________ ___________ _______________________ 4 ______________________________ _________ ___________ ___________ _______________________ 5 ______________________________ _________ ___________ ___________ _______________________ 6 ______________________________ _________ ___________ ___________ _______________________ 7 ______________________________ _________ ___________ ___________ _______________________ 8 ______________________________ _________ ___________ ___________ _______________________ 9 ______________________________ _________ ___________ ___________ _______________________ 10 ______________________________ _________ ___________ ___________ _______________________ COMMENTS: _______________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ SKETCH:

NOTE: COPIES OF MARKED-UP ISOMETRICS SHOWING BLINDING POINTS MAY BE USED IN LIEU OF A HAND-DRAWN SKETCH.

Documents

G3IR-1000-50-SP-9013_R1