HYDROSTATIC PRESSURE TESTING OF PIPING (PROJECT …

1 KLM TechnologyGroupProject :1of19 Rev: 01 July2011 KLM Technology Group#03-12 Block Aronia,Jalan Sri Perkasa 2 Taman Tampoi Utama81200 Johor BahruMalaysiaHYDROSTATIC PRESSURE TESTING OF PIPING (PROJECT STANDARDS AND SPECIFICATIONS)TABLE OF CONTENTSCOPE2 REFERENCES2 DEFINITIONS AND TERMINOLOGY2 UNITS3 PRESSURE TEST SYSTEM3 TEST WATER CRITERIA5 TESTING5 BLINDS FOR PRESSURE TEST6 TEST PACK PREPARATION6 General6 Test Pack Limits7 Test Pack Format7 Test Pack Approvals andDistribution8 Field Change Sheet (FS for PIPING )8 FIELD PIPE TESTING PROCEDURES8 PIPING Installation Completion8QC Clearance9 TESTING PREPARATIONS10 HYDROSTATIC TEST PROCEDURE11 SAFETY12 SENSITIVE LEAK TEST13 ALTERNATIVE TESTS13 Initial ServiceLeak test13 VESSELS AND EQUIPMENT13 INSTRUMENTS14 CLEANING14 REPORTS AND RECORDS14 TEST RECORDS15 APPENDIX A16 APPENDIX B18 APPENDIX C19 KLM TechnologyGroupProject Engineering StandardHYDROSTATIC PRESSURETESTING OF PIPING (PROJECT STANDARDS ANDSPECIFICATIONS)Page2of19 Rev.

2 01 July2011 SCOPEThis Project Standard and Specificationspecifies PRESSURE and leak testprocedure and acceptance criteria of PIPING works to perform minimum this Standard the following dated and undated standards/codes arereferred to. These referenced documents shall, to the extent specified herein,form a part of this dated references, the edition cited applies. Theapplicability of changes in dated references that occur after the cited date shallbe mutually agreed upon by the Company and the Vendor. For undatedreferences, the latest edition of the referenced documents (including anysupplements and amendments) Process "Welding and Brazing Qualifications"DEFINITIONS AND TERMINOLOGYC alculated Test PRESSURE -The test PRESSURE determined in this ProjectStandard and Specification D Fluid Service-A fluid service in which all the following apply (perASME ).

3 -The fluid handled is nonflammable, nontoxic, and not damaging to humantissues-The design gauge PRESSURE does not exceed bar-The design temperature is between-29 C and 186 CCategory M Fluid Service-A toxic fluid service in which exposure to very smallquantities of the fluid in the environment can produce serious irreversible harm topersons on breathing or bodily contact, even when prompt restorative measuresare taken (per ASME ).Damaging to Human Tissues-A fluid which, under expected operatingconditions, can harm skin, eyes, or exposed mucous membranes so thatirreversible damage may be done unless prompt restorative measures are measures may include flushing with water, administration ofantidotes, medication, etc (per ASME ).

4 KLM TechnologyGroupProject Engineering StandardHYDROSTATIC PRESSURETESTING OF PIPING (PROJECT STANDARDS ANDSPECIFICATIONS)Page3of19 Rev: 01 July2011 Minimum Test PRESSURE -The lowest allowable test PRESSURE gauge reading(the calculated test PRESSURE plus the additional PRESSURE resulting from the statichead of the test fluid).Maximum Test PRESSURE -The highest allowable test PRESSURE gauge reading(the PRESSURE test rating of the "weakest" component in the test system).UNITSThis Standard is based on International System of Units (SI) except whereotherwise , nominal sizes of PIPING component shall be inaccordance with inch systemPRESSURE TEST large a PIPING system as practicable including its associated equipmentshall be hydro tested together as a unit, unless the difference among theirdesign pressures exceeds 15 percentof the lowest design PRESSURE of thesystem test PRESSURE in the system shall be equal to the test PRESSURE applied tothe system component of which the design PRESSURE is the lowest among thesystem as mentioned in the following PIPING systems of different design pressures are fully welded together,then "cascade" PRESSURE TESTING will be required.

5 ( complete the pressuretest on the higher PRESSURE system prior to system closure welding and thenrepeat full PRESSURE Test Procedure for the test of the combined systems atthe lowest PRESSURE ). exchangers, PRESSURE vessels and fired heaters may be included in atest system, providing the system test PRESSURE does not exceed the shop testpressure of any of the included following equipment and components shall not be included in the equipment shall be isolated from the equipment such as pumps, compressors and valves rupture discs, flame arrest's, and steam vessels with sophisticated and PIPING lined with , if filter element(s) is not TechnologyGroupProject Engineering StandardHYDROSTATIC PRESSURETESTING OF PIPING (PROJECT STANDARDS ANDSPECIFICATIONS)Page4of19 Rev.

6 Exchangers of which tube sheets and internals have been designedfor differential PRESSURE between tube side and shell such as control valves, PRESSURE gages, level gages, andflowmeter (excluding thermocouples). followings areexcluded from the requirements of this package unit previously tested by the manufacturer in accordancewith the applicable systems, which are tested in accordance with the applicableplumbing and systems which are open to the atmosphere such as drain,vents, open discharge of relief valve, and atmospheric impulse lines between the block valve at the process or utilityline and the connected instruments shall normally beexcluded from the system.

7 Processlead lines shall be tested to the first block valve together with the vents or bypasses downstream of the instrument's first block valves shallbe opened or the instrument shall be disconnected during the test to insurefull protection of that test shall be HYDROSTATIC using water, except if there is a possibility ofdamage due to freezing, or if the operating fluid or PIPING material would beadversely affected by other suitable liquid shall be used with contractor's on site with Kerosene or other inflammable fluids or compressedair shall be avoided as far as possible (except where specifically calledfor) and shall be carried out only with the approval of a flammable liquid is used,its flash point shall be not less than50C andconsideration shall be given to the test TESTING shall be considered for the , steam, or vapor lines when the weight of the hydro test liquid wouldoverstress supporting structures or pipe with linings subject to damage by the hydro test instrument air headers shall be tested with dry-oil free air.

8 Thecommodity test may be used if the systems are completed and theinstrument air compressor is TechnologyGroupProject Engineering StandardHYDROSTATIC PRESSURETESTING OF PIPING (PROJECT STANDARDS ANDSPECIFICATIONS)Page5of19 Rev: 01 July2011 TEST WATER CRITERIACare shallbe taken to insure the use of clean water for HYDROSTATIC tests . And thesea water is prohibited to be suitable filter should be provided in the filling line to the systems in order toremove foreign matter such as sand, rust or other particles inthe proposed TESTING shall be performed using clam potable water with a chloridecontent of max 50 ppm for austenitic steels. In case this requirement can't befulfilled the pipeline shall be reamed completely and flushed with water fulfillingthe above requirement of 50 ppm max of TESTING of PIPING designed for internal pressureThe minimum HYDROSTATIC test PRESSURE at any point in the system shall be less than 1-1/2 times of the design a design temperature above the test temperature, the minimum testpressure shall be as calculated by the following Where.

9 Pt=minimum calculated HYDROSTATIC test PRESSURE (kg/cm2)P=internal design PRESSURE (kg/cm2)St=allowable stress at test temperature (kg/ cm2)S=allowable stress at design temperature (kg/ cm2)See Table I, Appendix A, IASME 1 When St and S are equal, test PRESSURE is x the test PRESSURE as defined abovewould produce a stress in excessof the specified minimum yield strength at test temperature, the test pressureshall be reduced to a PRESSURE at which the stress will not exceed thespecified minimum yield strength at the test TechnologyGroupProject Engineering StandardHYDROSTATIC PRESSURETESTING OF PIPING (PROJECT STANDARDS ANDSPECIFICATIONS)Page6of19 Rev: 01 July2011 The maximum test PRESSURE at which the stress produced will not exceed thespecified minimum yield strength may be calculated by the following Where:Pm= maximum test PRESSURE (kg/ cm2)S= specified minimum yield strength at test temperature (kg/cm2)t= specified pipe wall thickness minus mill tolerance (cm)D= outside diameter (cm)E= quality factor (see ASME table A-1 B) TESTING of PIPING Designed for External PRESSURE .

10 (Jacked limes) in external PRESSURE service shall be subjected to an internal testpressure of 1-1/2 times the external differential design PRESSURE but notless than a gauge PRESSURE of (15 psi). , the internal line shall be PRESSURE tested on the basis ofthe internal or external design PRESSURE , whichever is critical. This testshall be preformed prior to completion of the jacket shall be PRESSURE tested of the basis to the jacket systems require HYDROSTATIC TESTING through static equipment, thetest PRESSURE shall be selected so as not to exceed vessel test FOR PRESSURE TESTP lain test blanks shall be used with 1/16 inch flat asbestos gaskets for blankingflat face, and raised face.