PRESSURE TEST PROCEDURE FOR PIPING SYSTEM

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS
               
1.   SCOPE                                                                                         
2.   REFERENCES                                                                              
3.   GENERAL REQUIREMENTS
4.   PNEUMATIC TEST                                                                       
5.   EQUIPMENT FOR HYDROSTATIC TEST        
6.   PREPARATION OF THE TEST PACKAGE
7.   LIMITATION, EXCEPTIONS AND EXCLUSIONS
8.   FIELD PREPARATION
9.   PERFORMANCE OF PRESSURE TEST
10. EVALUATION OF TEST RESULTS
11. REPORT / DOCUMENTATION
12. REINSTATEMENT
13. ATTACHMENT 1 (TEST MANIFOLD)

1.0 SCOPE 
    1.1 This procedure covers the minimum requirements and plans for field pressure test of piping system for

          The EPCC of Two (2) nos additional crude Storage Tanks.

2.0 REFERENCE
    2.1 ANSI / ASME B31.3  - Chemical Plant and Petroleum Refinery Piping

3.0 GENERAL REQUIREMENT
    3.1 All piping lines shall be hydrostatic tested, but however, lines which where indicated in the line list may

          be service test.
    3.2 All lines which were indicated as a tie-in joint need to do 100% NDT such as RT, MPI or DPT and

          carry out the service test.
    3.3 The minimum test pressure shall be as specified in each piping Iso drawing or pressure test flow

          diagram based on ANSI / ASME B31-3 requirement.
    3.4 Test medium shall be fresh water, which clean and free from silt or un dissolved solids of any

          description.
    3.5 Test medium for austenitic stainless steel piping the water shall not contain more than 30 ppm chloride

          10N.
    3.6 All the equipment and lines, which are to be tested along with the piping, shall be blanked off or

          replaced with temporary spool pieces. Any test along the said item shall be approved by Contractor.
    3.7 All pressure gauge and pressure recorder used for the test shall be calibrated and registered in

          accordance with Calibration of Test/ Inspection Tools Control Procedure. Each certificate shall be

          valid for a period of three (3) months. Pressure gauge shall be selected so that the test pressure of the

          system falls between 30% and 75% of the gauge scale range. The following in line items will not be

          subjected to Field Pressure Testing:-
       1) Elements of strainers and filters
       2) Pressure relieving devices such as rupture disc, pressure valves etc.
       3) Locally mounted pressure gauge.
       4) Pressure measuring and regulating items such as flow control valves, turbine meters etc.
       5) Equipment like pumps, hose reels etc.
       6) Lines directly open to the atmosphere such as vents drains, safety valves, discharge etc. (conformation

           is required from Contractor)

4.0 PNEUMATIC TESTS
    4.1 Pneumatic test may be applied for certain lines and test pressure shall be 110% of design pressure as

          specified in each piping Iso drawing and / or pressure test flow diagram as per ANSI / ASME B.31-3

          requirement 345.5.4.
    4.2 The pressure shall be increased gradually until a gauge pressure which is the lesser of ½ the test

          pressure or 25 psi (170kpa) is attained and held for 10 minutes, at which time a preliminary leak check

          shall be made with soap solution on all joint. The pressure shall be increased in steps of 25%, 50%

          and 75% of the test pressure. At each step the pressure shall be held for sufficient time to allow the

          piping to equalize strains. After holding at test pressure for 10 minutes, the pressure shall be reduced

          to the design pressure for leakage examination. Leak testing of joints shall be done with soapy water.

          Safety precautions shall be taken by placing a safety relief valve on the system under test.
    4.3 The set pressure of the relief valve shall be set at a pressure not higher than the test pressure plus the

          lesser of 50 psi (340kpa) or 10% of the test pressure

5.0 EQUIPMENT FOR HYDROSTATIC TEST
    5.1 Equipment for hydrostatic test shall be properly designed and in good working order and shall be

          compatible with the pressure and capacity required during the test.
    5.2 The following equipment will be provided in order to conduct the hydrostatic test but not necessarily be

          limited to the following:-
        1) One high volume pump
        2) One portable tank to provide a source of pressurizing water
        3) One hand pump for pressurizing
        4) Pressure gauges and temperature gauges
        5) Pressure recorder
        6) Safety relief valve (only for pneumatic test)
        7) Test manifolds (if required)

6.0 PREPARATION OF TEST PACKAGE
    6.1 Prior to commencement the Field Hydrostatic Test the piping test package shall be prepared and

          submitted to the Client Inspector for review / approval.
    6.2 The following documents will be included in the test package:-
        1) Piping test package certificate
        2) Test block diagrams
        3) Signed off punch list
        4) Signed off Q.C check sheet
        5) Q.C Iso drawing
        6) Pressure Gauge calibration Records (calibration certificates)
    6.3 When the documents in test package are proper and approved by the Contractor. Line check shall be

          made in accordance with approved procedure prior to the test.
    6.4 All welds to be pressure tested shall be free of paint, thermal insulation coating and wrapping.

7.0    LIMITATION, EXCEPTIONS AND EXCLUSIONS
    7.1 Where the test pressure of piping attached to a vessel is the same as or less then the test pressure for the vessel, the piping may be tested with the vessel at the test pressure of the piping.
    7.2 Where the test pressure at the piping exceeds the vessel test pressure and it is not considered

          practicable to isolate the piping from vessels, the piping and the vessels may be tested together at the

          test pressure of the vessels, when approved by the owner, and provided the test pressure is not less

          77% of the piping test pressure. (ASME B 31.3)(337.4.2)
    7.3 The equipment or piping which is not subjected to the test shall be blinded off from the piping to be

          tested.

8.0    FIELD PREPARATION
    8.1 When the whole length of system to be tested is completely installed and boundaries are checked by

           Subcontractor Q.C
    8.2 Test manifold shall be provided in order to supply water to the system, install pressure gauge,

          temperature gauge and safety relief valve.
    8.3 Pressure gauge shall be provided at two points where one is to be located at highest location in the

          system and the other at the manifold.
    8.4 All test blanks required for pressure test shall have sufficient thickness to ensure safety during test or

          permanent blinds may be used for the field pressure testing.
    8.5 Prior to commencement of the hydrotest, all hot works shall be completed.

9.0    PERFORMANCE OF HYDROSTATIC
    9.1 All vents and other connections which can serve as pressure test vents, shall be open during filling so

          that air can be vented prior to applying test pressure to the system.
    9.2 The system shall be filled with fresh water by use of electrical or hand pressurizing pump until the

          intended pressure, slowly and gradually.
    9.3 While the system is being pressured all weld joints will be visually inspected for any leakage.
    9.4 Once attained, the intended test pressure shall be held for a period of 30 minutes minimum or such

          time as required for full visual inspection of the system.
    9.5 Any joints found leaking during the pressure test shall be retested to the specified test pressure after

          repair have been made.
    9.6 After hydrostatic testing of the system is completed, all lines and equipment shall be drained

          completely. The system shall be vented while draining to avoid vacuum.
    9.7 All pressure test must be witness and report to be endorsed by Client rep.

10    EVALUATION OF TEST RESULTS
    10.1 If there is no leakage during the test it will be considered as accepted and     test report to be

            endorsed by Client.

11    REPORT / DOCUMENTATION
    11.1 After pressure test, the pressure test records and the post-test punch items shall be signed off by

           Subcontractor approved by Contractor and endorsed by PPM’s rep. All this documents shall be

           compiled into the Test package.

12    REINSTATEMENT
    12.1  After completion of hydrostatic test, all the system shall be reinstated as per the approved drawings.