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PRESSURE TESTING PROCEDURE

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1.0

SCOPE

This procedure pertains to activities related to pressure testing of steel pipe work during Construction Works in order to ascertain the integrity and proper installation condition of the pipings prior to commissioning. 2.0 REFERENCES - Standard construction specifications: ASME B31.4
3.0 RESPONSIBILITY

3.1 3.2 3.3

The Construction Manager shall be responsible for the implementation of this procedure The Mechanical Supervisor shall be responsible for correct application of this procedure The QA/QC Engineer shall be responsible for inspection activities related to this procedure by way of QC inspection personnel and also for collection and filling of QC documentation.

4.0

EQUIPMENT AND PRESSURE TEST FACILITIES

The equipment to be employed for pressure testing shall be of good working condition and from recognized manufacturer. They include the following : 4.1 4.2 4.3 Pressurizing Pumps Calibrated Test Instrument e.g. Pressure gauges, Thermometers, Pressure and Temperature recorders Water Filling (Portable) with flow-meter.

*calibration of test instrument shall be performed by a competent person using specific devices (i.e. dead weight tester, etc.) prior to testing.
5.0 PROGRAM AND TESTING SCHEDULE

The programme and testing schedule shall be submitted to NAOC for approval/comments before test preparations are due to start. In addition, at least 48 hours notice shall be given to - representative stating actual date and time such tests, checks and inspections are due to commence. Testing schedule shall be developed prior to any hydro-testing , detailing the installation to be tested, determine the test section , test pressure and duration and preparing isometric for each section to be tested and construction of temporary works and test provision. The test section shall clearly be identified by isometrics and P&I drawings. This is to ensure that each has sufficient vents and drains.
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6.0

PRE-TEST PREPARATION AND CHECKS

Operations prior to introduction of test medium 6.1 Prior to proceeding with any hydrostatic testing of Piping the following documentation shall be prepared and where appropriate signed by both RAMM TECHNICAL SERVICES LIMITED and representatives . Checklist Piping erection Report Erection acceptance Report Pipe Testing Reports

a) b) c) d)

6.2 Two Pressure Gauges (calibrated) shall be installed with pressure rating not exceeding 1.5 times of test pressure. The gauges where possible, shall be at the lowest and highest elevation but shall be in any case at the maximum distance possible away from one another. 6.3 All valves in the test section shall be in the open position (Ball valves and plug valves 1/2 open) unless specifically directed otherwise in writing by clients representative. Relieve valves and bursting discs shall be removed and their connections blanked off. 6.4 It shall be ensured that during pressure testing thrusts or forces can occur during the test. no movement,

6.5 Prior to flushing of pipe works, all control valves shall be removed and replaced with spool pieces 6.6 Prior to flushing all isolating valves of the level gauges shall be in the closed position. After flushing the isolating valves of the level gauges shall be opened where applicable. 6.7 All safety valves shall be removed before flushing and shall be checked by client for popping and sealing where applicable 6.8 Flow meters shall be removed before flushing and reinstalled upon completion of the hydrotesting. Where required spool pieces shall be installed. 6.9 Filter elements of strainers shall be removed before flushing and reinstalled before hydrotesting. 6.10 The open drain/closed drain pumps shall be removed before flushing and reinstalled upon completion of hydrotesting. Pumps shall be replaced with spool pieces.

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6.11 Pressure gauge connection shall be blinded off before flushing and reinstalled upon completion of hydrotesting. 6.12 All impulse line shall be disconnected from the process equipment or piping prior to flushing and reconnected after completion of the hydrotests. 6.13 Continuos recording of hydrostatic pressures and ambient temperatures throughout the test duration on approved calibrated recorders. 6.14 The following items shall either be removed and replaced with temporary spool pieces or isolated by blanks - safety valves
- control valves - equipment/machinery - instrumentation 6.15 The items to be tested shall be adequately vented and drain facilities available where possible.

7.0

PRESSURE TESTING AND INSPECTION

7.1 Water shall be introduced to the piping system to be tested from the lowest point and all vents left opened until air has been expelled. 7.2 The system shall be flushed until the flushing water leaving the system is clean. 7.3 The system shall then be pressurized at a moderate constant rate of 1.5 bar every 20 minutes, i.e. pressurization is stopped and the system checked for leaks at 20 minutes intervals. 7.4 Allow for stabilization period when the pressure is 70% of the test pressure. 7.5 Vents shall be closed for several hours until such a time is established that the temperature of the water within the tested section has completely stabilized. 7.6 At this point checks shall be carried out for leaks and such leakage rectified when necessary as per ASME B31.4 Where repairs to leaks may require hammering of studbolts or the use of air-impact wrenches, the system shall be depressurized. 7.7 The system shall then be pressurized to the required test pressure of 1.5 MOP of the weakest link in the system under test and shall be kept at

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that pressure for 24 hours test duration. The test pumps shall then be disconnected for the duration of the 24 hour hold period and the connections capped or plugged off. 7.8 Repairs and Re-test shall continue until the specified test pressure can be satisfactorily maintained for the specified test duration. 7.9 Should client consider that the result of the test duration, pressure and leakage test are inconclusive, we shall extend the test for a period equal to the test duration of extra time as client may consider necessary in order to obtain conclusive result.
8.0 DEPRESSURIZATION AND WATER DISPOSAL

On completion of the Test duration and acceptance obtained from client, the system tested shall be depressurized and water used for the test disposed. The disposal of the test water shall be as directed by representative. Blanks shall be removed where applicable, Gaskets & Bolts replaced and bolts finally tightened.
9.0 PNEUMATIC SOAP BUBBLE TEST

The entire system shall be subjected to a pneumatic soap bubble test at a maximum pressure of 5 bars. Test shall be performed on all flanged joints, bonnets and glands of items which were not subjected to the hydrostatic test with a detergent soap solution. Any leak evidenced by the formation of bubble shall be rectified. Note: Pneumatic soap bubble test to be done only after Precommissioning activities have been completed.
10.0 COMPLETION OF HYDROTEST AND TEST REPORTS

Test reports and charts shall be submitted to client for approval after satisfactory completion of the pressure test and the reports shall contain the following information: - confirmation of the starting time - date - the system under test and installation name - the recorder element range - test start and stop signatures - who witnessed and accepted the test on behalf of client.

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Test shall be started and stopped in the presence of the persons authorised to witness these tests on behalf of client. On no account shall closed valves be utilized for pressure containment in a system under test. The containment shall be effected by suitably rated spades, blind flanges or welded on dome end caps. Upon completion of the hydrotest of the piping system, the leak-free tightness of any valve specified as 100% tight shut-off shall be verified.
11.0 SAFETY

Safety of all employees and the public during the pressure testing is of paramount importance and this can be achieved by the following viz: - Availability of sufficient and efficient Safety personnel - The whole area under test shall be barricaded with rope and appropriate warning signs e.g. KEEP OFF PIPING UNDER PRESSURE shall be put in place. - Human traffic shall be controlled by dedicated personnel - Fire watch/extinguisher shall be dedicated and safe hand tools shall always be used - Hydrotesting personnel shall at all times be in liaison with CASHES officer - The system under test most be adequately vented to exclude any possibility of air pockets - Blanking-off shall be ensured to be of correct rating and that such items, in particular screwed plugs and connections, are not liable to be ejected during testing, e.g. as a result of thread failure or inadequate thread engagement - System shall not be subjected to any form of shocking loading, such as hammer testing whilst undergoing strength tests - Systems subjected to maximum test pressure should not normally be approached for close inspection until after a reasonable period of time has elapsed - Sea water shall be considered as a testing medium for systems where fresh water is unavailable. However, this shall be done only with prior written permission of -. In all cases where sea water is used this must first be inhibited. There will be cases where inhibited sea water is unsuitable and in such circumstances special provisions must be made to obtain clean fresh water.

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- Where a pressurizing medium other than water is used, care shall be taken to identify any additional hazard associated with the liquid concerned.

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