Es 14 602 02

Inspection and Testing of Piping Systems
ES-14-602-02
This is a Controlled Document that complies with

Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards.
Please check that this is the latest available version before use.
Title:
INSPECTION AND TESTING OF PIPING SYSTEMS
Number:
ES-14-602-02
Version Number:
12.0
Date Revised:
25 January 2013
Owner:
Phillip Brown
Authoriser:
Manoj Thakur
Reasons for Creating

or Amending
Document
New Authoriser
Actual Change Details:
Control Block updated; New Authoriser - Manoj Thakur; No

changes to contents of document
Full Review of Document
TABLE OF CONTENTS
1.
SCOPE ................................................................................................................................................... 3
1.1
2.
DEFINITION OF TERMS ................................................................................................................ 3

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
3.2
3.3
3.4
3.5
3.6
4.
QUALITY PLANS ............................................................................................................................ 7

INSPECTION AND TEST PLANS .................................................................................................. 8
PUNCHLISTING / ACCEPTANCE ................................................................................................. 8
MANUFACTURERS DATA REPORT .......................................................................................... 8
CERTIFICATION OF MATERIALS TEST DATA ......................................................................... 9
INSPECTION BY THE SUPERINTENDENT ............................................................................... 10
PRELIMINARY ACTIVITIES ......................................................................................................... 10
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ES-14-602-02
4.1
4.2
4.3
4.4
4.5
5.
DESIGN REVIEW .......................................................................................................................... 10

TEST PACK .................................................................................................................................... 11
CSBP DESIGN REVIEW ............................................................................................................... 12
OPERATOR TRAINING ................................................................................................................ 12
SAFETY SYSTEM CHECKS......................................................................................................... 12
STAGE 1 - INSPECTION AND CONSTRUCTION VERIFICATION ........................................ 13
5.1
5.2
5.3
6.
NON DESTRUCTIVE EXAMINATION - PIPING AND FITTINGS ........................................... 13

BRANCH WELDS AND REINFORCING PADS ......................................................................... 16
HARDNESS TESTING .................................................................................................................. 16
STAGE 2 - TESTING ......................................................................................................................... 16
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
PUNCHLISTING PIPING SYSTEMS ........................................................................................... 17

SYSTEM FLUSHING..................................................................................................................... 19
WITNESSING PIPING SYSTEM PRESSURE TESTING ............................................................ 20
HYDROSTATIC TESTING ........................................................................................................... 20
SYSTEM DRYING ......................................................................................................................... 25
CHEMICAL CLEANING OF PIPING SYSTEMS ........................................................................ 25
PNEUMATIC TEST PROCEDURES ............................................................................................ 26
LEAK TESTING OF PIPING SYSTEMS ...................................................................................... 26
AIR BLOWING OF PROCESS PIPEWORK ................................................................................. 31
STEAM BLOWING OF TURBINE PIPEWORK .......................................................................... 32
SETTING SPRING PIPE SUPPORTS ........................................................................................... 34
RE-INSTATEMENT OF PIPING SYSTEMS ................................................................................ 34
NITROGEN PURGING .................................................................................................................. 35
PIPING TIE-INS TO EXISTING PLANT ...................................................................................... 35
POST COMMISSIONING CHECKS ............................................................................................. 35
APPENDIX 1 - FLUID SERVICE PIPING SYSTEM INSPECTION CLASSIFICATION FLOW

CHART ........................................................................................................................................................... 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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ES-14-602-02
1.
SCOPE
This Standard covers the minimum requirements and acceptance criteria for the inspection and
testing of piping systems. The work shall be carried out in two stages as follows:
Stage 1
Inspection and verification, that all items have been supplied and installed in accordance with
drawings and manufacturers requirements.
Stage 2
The testing of piping systems, to verify the integrity of the piping system, prior to putting into
service.
Should there be conflict between these standard, local or statutory requirements, the Superintendent
shall be consulted in writing, for resolution. In general, the most stringent requirement shall
prevail.
Note:
1.1
The Contractor shall not subcontract any work without the prior approval by the
Superintendent in writing.
DEFINITION OF TERMS
Contractor/Vendor
The Company that provides the services needed.
Sub-Contractor
A third party to be employed by the Contractor/Vendor who has been approved by the
Superintendent.
Superintendent
CSBP Limited, or authorised representative.
CSBP
CSBP Limited.
Works
The Scope of Work that a Contractor is or may be required to execute under an agreement
including variations of remedial work.
Actions
Shall, Will or Must indicates mandatory action.
Should, indicate preferred / recommended action.
May or Can indicates possible or optional action.
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ES-14-602-02
2.
APPLICABLE CODES AND STANDARDS
The Contractor shall perform the works in accordance with the most recent issue of the applicable
standards 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.
Manufacturers 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
2.3
Take 5 and Job Safety Analysis Risk Assessment
CSBP STANDARD FORMS
Stage 1 Commissioning Inspection Reports

M146
M147
Pipelines
Pipeline Valve Operation
Stage 2 Commissioning Test Reports

M246
M247
Pipelines
Pipeline Valve Operation
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ES-14-602-02
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 for
High Temperature Service
A106
Seamless Carbon Steel Pipe for High Temperature Service
A181
Forged or Rolled Steel Pipe Flanges, Forged Fittings, and Valves and Parts for
General Service
A182
Forged or Rolled Alloy - Steel Pipe Flanges, Forged Fittings, and Valves and Parts
for 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 Piping
Components
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 Valves
594
Wafer and Wafer-Lug Check Valves
597
Steel Venturi Gate Valves
598
Valve Inspection and Testing
599
Metal Plug Valves - Flanged and Welding Ends
600
Steel Gate Valves, Flanged and Buttwelding Ends
602
Compact Steel Gate Valves
607
Fire Test for Soft-Seated Quarter-Turn Valves
609
Lug and Wafer Type Butterfly Valves
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ES-14-602-02
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 Qualifications
B31.3
2.8
Chemical Plant and Petroleum Refinery Piping
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
AS 1650
Hot Dipped Galvanised Coatings on Ferrous Articles
AS 2022
SAA Anhydrous Ammonia Code
AS 2032
Code of Practice for Installation of UPVC Pipe Systems
AS 2129
Flanges for Pipes, Valves and Fittings
AS 2430
Classification of Hazardous Areas
AS 2528
Bolts, Studbolts and Nuts for Flanges and Other High and Low Temperature
Applications
AS 3678
Structural Steel - Hot Rolled Plates, Floor Plates and Slabs
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ES-14-602-02
AS 3679
Structural Steel
AS 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 other
Piping Components (visual method)
BS6755
Part 2 - Specification for Fire Type - Testing Requirements
3.
QUALITY SYSTEMS
Unless otherwise approved by the Superintendent, the Contractors Quality System shall comply
with 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 copy
of the certificate shall be provided to the Superintendent upon request. The Contractor shall also
provide to the Superintendent such information as the Superintendent may require to demonstrate
that 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, the
Contractor shall ensure that the manufacturer(s) comply with all specified QA requirements.
The Superintendent may audit the Contractors or Subcontractors Quality System at any time. The
Contractor shall assist in carrying out such audits and shall rectify any deficiency identified by the
date 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, for
any 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 the
work under the Contract.
The Quality Plan shall include an organisation chart detailing the name position and reporting
relationship of these personnel. It shall also include a summary of the responsibilities of the
personnel shown on the organisation chart.
Submission of the Quality Plan to the Superintendent is required within twenty-eight (28) days of
Notification of Acceptance of any work covered by this Standard or as detailed in the Works.
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ES-14-602-02
3.2
INSPECTION AND TEST PLANS
The Contractor shall also provide Inspection and Test Plans (ITP) for all aspects of the Works.
These shall identify:
a.
The inspection, tests and verifying procedures (hereinafter referred to as procedure(s)) to be

performed including those detailed in the Contract.
b.
The acceptance criteria for each procedure, the codes, standard or process under which they
are to be performed.
c.
The point, during the work under the Contract, at which the procedure is to be performed.
d.
Who is to perform the procedure.
e.
The procedures to be witnessed by the Superintendent and whether or not subsequent work
is to be held pending the Superintendents approval of the procedures and results there
from.
ITPs shall be submitted to the Superintendent for approval as detailed in the Works or no later
than 14 days prior to the commencement of any work under the Contract, which may be affected.
The Contractor shall not proceed with any related work until the Superintendents approval has
been received. When a procedure is not in accordance with the recognised standard or code of
practice, the Superintendent requires that details of the proposed procedure be submitted for
approval prior to work proceeding.
The Contractor shall provide the Superintendent with a minimum of five (5) days notice in writing
of any procedure that requires witnessing by the Superintendent in Australia and fourteen (14) days
for overseas.
3.3
PUNCHLISTING / ACCEPTANCE
The Contractor shall submit for approval the procedure, which details the process for punch-listing
of the work under the Contract.
3.4
MANUFACTURERS DATA REPORT
The Contractor shall provide the Superintendent with a Manufacturers Data Report (MDR) from
each manufacturer providing equipment or fabricated items for the work under Contract. Each
MDR shall be progressively compiled by the manufacturer and shall be submitted to the
Superintendent upon completion of manufacture of the equipment or fabricated items to which it
relates.
Piping shall not be released or accepted by the Superintendent until such time as the associated
quality records have been reviewed and accepted by the Superintendent.
For details of the MDR content and format refer to Manufacturers Data Report (MDR) Plant
Projects (EP-08-030-37).
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ES-14-602-02
3.5
CERTIFICATION OF MATERIALS TEST DATA
The following types of certificates are specified to verify that the requirements of the Contract are
met:
Type I:
(Equivalent to DIN 50049-2.2)
Certificates on which the Contractor confirms, on the basis of the test results from the inproduction testing of products of the same material and same manufacturing method as the
equipment concerned, that the equipment supplied corresponds with what was specified.
Type II:
(Equivalent to DIN 50049-3.1B)
Certificates on which the Contractors inspector confirms, on the basis of tests carried out on the
equipment itself or on standard specified test specimens related to the equipment, that the
equipment supplied corresponds with what was specified. A testing centre that has no connection
with the production in the manufacturing works and which has the necessary facilities at its
disposal must have carried out the necessary testing. When the independence of the testing centre
is 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 by
Superintendent 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.
Manufacturers 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,
j.
Where applicable, NDT methods and results,
k.
Where applicable, heat treatment procedures, furnace charge number and heat treatment
records, and
l.
Supplementary or additional requirements.
All Type III Certificates additionally shall specify:

a.
The name of the independent inspector who witnessed the test(s), and
b.
The inspectors identification symbol. If not otherwise specified, the material concerned
should be hard stamped (low-stress dies) with an identical symbol.
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ES-14-602-02
3.6
INSPECTION BY THE SUPERINTENDENT
The Contractor will specify on the ITPs the inspections and tests at which the Superintendent will
attend. The Contractor shall provide at least five (5) days notice in writing of the inspections or
test dates for procedures to be witnessed in Australia and fourteen (14) days for overseas.
Notwithstanding the tests and inspections specified for the Superintendents attendance, the
Superintendent 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 the
necessary inspections.
4.
PRELIMINARY ACTIVITIES
4.1
DESIGN REVIEW
The Contractor shall carry out a design review in order to facilitate inspection and testing work and
defining the approach to be taken.
When all HAZOP studies and CSBP Design Reviews have been completed and the P&IDs are at a
stage where they have been frozen the Contractor shall:
a.
Review and mark up P&IDs to determine extent of each Test Pack and to define total
number 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 weight
of 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 Packs
required as a result of maximising test limits.
e.
Prepare a master set of colour coded P&IDs 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.
i.
Calculate and tabulate a comprehensive list of carbon steel, test spade thicknesses required
for the maximum non-shock flange rating for each Piping Specification Class.
j.
Identify any lines that require additional temporary support during hydrotesting.
Note:
Any changes in test pressures, drawings and documentation due to the design review shall
be submitted to the Superintendent for approval.
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ES-14-602-02
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 to
make up complete test packs. Each Master Test Pack, for the systems identified by the Contractor
during the Design Review, shall include the following minimum information:
a.
Test Pack lead sheet identifying Line Number, Isometric Number, P&ID Number, Test
medium, Test pressure and extent of test.
b.
Marked up a set of P&IDs identifying Test Pack and delineating test boundaries.
c.
Authorisation sheet allowing vessel to be included in test (where applicable). Refer to

APPENDIX 4 for example.
d.
Stored energy calculations/exclusion zone distances for pneumatic tests as per AS3788
Appendix 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 isometrics
showing:
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 (for
pneumatic tests).
The Contractor shall submit the Master copy of each Test Pack to the Superintendent for
acceptance.
If Master Test Pack is accepted without comment the Superintendent shall sign and return this
document to the Contractor who shall prepare copies as described in the Works, or as directed by
the Superintendent.
If the Superintendent makes comment, the Master will be returned to the Contractor for correction
and resubmission.
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ES-14-602-02
4.2.2.1
Test Pack Identification Colours
For ease of identification Test Packs shall be colour coded. An example is as follows:
4.3
Master Test Pack
Blue Folder
Welding/Traceability Test Pack
Green Folder
CSBPs copy (2 required)
Buff Folder
Contractors copy
Purple Folder Testing
Contractors copy
Red Folder
Spare/Working Field Copies
Yellow Folder
CSBP DESIGN REVIEW
At the end of the design phase CSBP shall conduct an Operability and Maintenance review as per
CSBP Engineering Procedure Engineering Project Design Review (EP-08-030-19)
This review is designed to supplement the HAZAN & HAZOP studies and identify any areas
where 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 that
operational or maintenance difficulties may be encountered in the future the Contractor shall bring
it to the Superintendents attention immediately.
4.4
OPERATOR TRAINING
During the final stages of Construction, the Superintendent shall commence Operator training
activities. Whilst this does not impact Contractors scope of work there may be areas where
Contractor can impart specialised knowledge or information regarding equipment to CSBP
personnel.
4.5
SAFETY SYSTEM CHECKS
It is the Contractors responsibility to perform all work in a safe manner and to identify all
potentially hazardous activities. A Job Safety Analysis (JSA) review shall be carried out prior to
starting work. The Contractor shall submit the JSA record to the Superintendent for approval prior
to commencing the activity, which was the subject of the JSA. For guidance, refer to CSBP
document Take 5 and Job Safety Analysis Risk Assessment (GM-11-031-23).
The Contractor shall prepare a Safety Management Plan for the Superintendents approval.
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ES-14-602-02
5.
STAGE 1 - INSPECTION AND CONSTRUCTION

VERIFICATION
All components within the piping system shall be inspected to verify that they have been
fabricated/manufactured, supplied and installed in accordance with:
a.
Contract drawings and documentation,
b.
Standards and Codes specified in this Standard,
c.
Local and Statutory Regulations,
d.
Manufacturer's requirements.
Stage 1 Commissioning Inspection Reports: Pipelines (M146) and Pipeline Valve Operation
(M147) shall be used to verify equipment details. The Contractor shall perform their inspection
using the commissioning inspection reports, and when they are satisfied that the system is ready,
contact the Fabrication Inspector or Field Supervisor (whichever is nominated by the
Superintendent) who will then audit the Contractors inspection. Any items found to be incomplete
on the checklist shall be added to the piping punchlist. Items on the Punchlist should be signed off
progressively after individual item verification has taken place. Stage 1 Commissioning Inspection
Reports shall be signed off after the Punchlist sign off has taken place.
Stage 2 Commissioning, shall not commence until the Superintendent has accepted and signed off
Stage 1 Commissioning Inspection Reports, as being successful completed.
The inspection reports and punch-lists shall form part of the final MDR.
5.1
NON DESTRUCTIVE EXAMINATION - PIPING AND FITTINGS
Inspection classification of fluid piping systems shall be in accordance with APPENDIX 1. Refer
to CSBP Engineering Standard Basis for Design - Piping (ES-14-601-01) for individual fluid
service weld inspection requirements.
The Contractors non-destructive examination (NDE) shall not be less than the percentages shown
in Table 1. These percentages shown refer to Shop and Field welds. Additional radiographs on
any defective welds or repairs shall be to the Contractors account. For welds that are radiographed
the weld surface shall be sufficiently smooth to allow for proper evaluation to ASME VIII.
Final non-destructive examination to the minimum required by Table 1, shall be performed after
any post weld or post fabrication heat treatment.
The acceptance Standards for the non-destructive examination shall be in accordance with ASME
B31.3.
The inspector representing the Superintendent will nominate the specific welds to be radiographed.
For jacketed piping all circumferential and longitudinal welds in the inner pipe shall be 100%
radiographed in accordance with Inspection Class 4.
All piping is subject to 100% visual inspection. Visual inspection shall be done before, during and
after welding, prior to painting or any other surface treatment.
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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 other
stress raisers.
The following items shall be checked for compliance with CSBP Engineering Standard Fabrication
and 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 is

involved 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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ES-14-602-02
Inspection Class
Visual
(G)
100%
(E) (F) (D)
100%
(E) (D)
100%
(E) (F)
100%
(E)
100%
6
7
Radiographic or
Ultrasonic
Radiographic
MPI/Dye Penetrant (A)
5% (C) (H)
5% (C) (H)
20% (C) (I)
20% (C) (I)
100%
100%
100% (B)
100%
100%
(G)
100%
LEGEND
(A) Magnetic particle inspection (MPI) or dye penetrant testing is only required where weld CANNOT be
radiographed, 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 subject
to full visual, radiographic, ultrasonic (for 12mm thickness and above) and MPI/Dye Penetrant
examination.
(F) Inner process pipe of jacketed lines to be examined in accordance with Inspection Class 4. Associated
outer pipe to be in accordance with class specified for the jacketing fluid in CSBP Engineering Standard
Basis for Design - Piping (ES-14-601-01).
(G) 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.
(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.
(J) An in position weld is defined as a weld performed with the piping in its final position in the field, or
final position with a skid mounted unit.
(K) Where the applicable % of welds results in a fraction. (eg: 5% of 22=1.1), then the number of welds to be
inspection shall be rounded up to the next whole number (for 5% of 22 it would be rounded up to 2).
Table 1 Non Destructive Examination
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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 shall
merge smoothly with the surface of the pipe with no notches or undercutting permitted. Sharp
corners on reinforcing pads shall be removed.
5.3
HARDNESS TESTING
Brinnell hardness testing shall be performed on heat-treated welds in accordance with ASME
B31.3, 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 a
criteria (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 atmospheric
sewers, unless noted otherwise on design documentation
b. Where the Superintendent, Area Plant Engineer, and Senior Plant Inspector have authorised
that no test is required. The approval of the pressure testing waiver and the reason for the
waiver 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 in
this Standard. The test pressures shall be as indicated on the piping isometrics/line list.
For non-metallic piping, if a clear comprehensive test method is given in the applicable Australian
or international standard for that piping material, or in the manufacturers recommendations, then
that method may be used instead of parts of the method given in section 6.4. In the absence of any
clear alternative method, then ASME B31.3 and section 6.4 shall be followed.
Where approved by the Superintendent, Area Plant Engineer and Senior Plant Inspector, specific
requirements of sections 6.1.1 and 6.4 may be relaxed, and the deviations and approval of the
deviations recorded on the hydrostatic test record, ITP or other quality record included in the MDR.
Examples of some relaxations that may be granted are in 6.4.14.
Non-essential personnel shall be excluded from the immediate test area. Refer Section 4.2.1 for
pneumatic test exclusion zones. For hydrostatic test, the following may be used as a guide:
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1m
150# rated systems,
2m
300#, 600 and 900# rated systems
5m
1500# systems and above.
Note:
Unless there is a reason to suspect the condition of the welds or pipe, or the system is
1500# or above the restricted area may be confined to around flanges, valves and other
likely leak points.
6.1
PUNCHLISTING PIPING SYSTEMS
6.1.1
Pre-test Punchlisting
Piping systems shall be punchlisted by test pack initially in Pre-test format to maintain the
pressure testing schedule, and following a successful test of the system a Post-test punchlist shall
be issued to the Contractor.
Inspections shall be performed using the Stage 1 Commissioning Inspection Reports described in
Section 5 (M146 and M147). Items that are incomplete or unsatisfactory shall be placed on a Pretest Punchlist.
Atmospheric lines, which cannot be tested, are subjected to a visual examination only, with the
relevant parts of the Stage 1 Commissioning Inspection Reports still being inspected and
punchlisted. For record purposes, the Pre-test punchlist shall identify all No Pre-test punch list
items.
The Pre-test punchlist shall confirm that all welding, including welded attachments, has been
complete and the system is ready to be pressure tested.
The Superintendents Field Supervisor or Fabrication Inspector (nominated by the Superintendent),
who shall be responsible for the preparation of the punchlist, shall conduct an inspection of the
system after the Contractor has performed their own inspection and advised that the system is ready
for testing. Simultaneously, the Contractors Quality Manager will satisfy the Superintendents
Fabrication Inspector that all welding and NDE is complete and that all components meet the
traceability requirements of the specification.
The Piping Field Test Report (PFTR), which is the lead sheet in the test pack, provides
authorisation for a test to proceed. An example PFTR can be found in APPENDIX 7. It shall not
be signed off until all pre-test punch list items have been cleared, all NDE is complete and the
Stage 1 Commissioning Inspection Reports are complete.
Contractor is to confirm the following:
a.
The Fabrication Inspector(s) has cleared all NDT/Traceability records and the Test Pack
has been signed accordingly.
b.
All pre-test punch list items have been completed and the Test Pack signed off.
c.
The latest revision of isometrics are included in the Test Pack.
d.
Correct thickness of test spades, blinds and gaskets are installed.
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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 in
normal operation.
h.
All inline instruments have been removed (except thermowells) and signal and impulse
lines disconnected.
i.
All vents, drains and primary instrument connections have been plugged / capped and all
valves are open.
j.
All control valves have been removed and stored in a safe location with flange faces
protected.
k.
All equipment has been spaded off and precautions taken to ensure that test or flushing
water cannot enter equipment. (especially compressors) Testing through equipment is by
exception 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 Superintendents Safety Department
notified.
A test may not proceed until both the Superintendents Fabrication Inspector and
Piping/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 fortyeight hours prior to hydrotest and five working days in the case of a pneumatic test. Refer to
APPENDIX 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 test
spades/blinds etc. and re-instate all in-line instruments and valves. The Superintendent shall then
prepare 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 Commissioning
Reports: Pipelines (M246) and Pipeline Valve Operation (M247). To supplement the Stage 2
Commissioning Reports, the Contractor shall prepare a reinstatement pack to go with every test
pack, or piping system where piping is not hydrostatically or pneumatically tested. The
reinstatement pack is to be checked during the Stage 2 commissioning report inspections. The
reinstatement pack shall consist of:
a.
Copies of test pack drawings highlighting spade, blank and plug locations, removed items,
correct flow direction for unidirectional items, and other special items or actions, which
need to be removed, installed or performed to ensure correct reinstatement of the piping
system.
b.
Copies of drawings and documents showing support locations and details.
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c.
A list of special items which may not be obvious to the person reinstating the piping
system. 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 prepared
using 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 the
number of post test punchlists issued, total number of punchlist items, how many were cleared in
the 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. Gauges
shall 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. The
original chart record of pressure versus time, and temperature versus time shall be included in the
Master Test Pack. Unless otherwise agreed by the Superintendent a chart recorder shall be used for
hydrostatic 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 thoroughly
flushed. On large and diverse systems, several return lines to the tanker may be necessary.
The Contractor shall furnish and install flushing screens (temporary strainers) on the upstream side
of all equipment. After flushing, items shall be removed and all resulting debris removed from the
work site by the Contractor.
The Superintendent shall be the sole judge of the cleanliness of the piping system.
Volume of water for flushing shall be sufficient to provide a continuous flow for at least fifteen
minutes. High volume low-pressure pumps shall be employed to ensure that any debris within the
lines is removed.
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Flushing by air shall be subject to approval by the Superintendent. Where used, except as defined
in Section 6.9, Contractor shall ensure that volume is sufficient to blow out any debris. Exit
locations for air blowing shall be chosen to ensure safety of personnel and consideration shall be
given 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) days
before 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 safety
warning and advises that a pressure test is being conducted. Refer to Section 6 for guidelines on
exclusion 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 system
pressurisation and only those personnel directly involved with the test may enter to conduct and
witness the soap tests at designated hold periods.
Contractor shall provide safe access to every weld / screwed connection for the Superintendents
Inspector.
All pressure tests shall be witnessed by an approved NATA endorsed Inspector and by the
Superintendent, at his discretion.
Following examination and acceptance of the system, the recorder charts and the PTFR in the
Master Test Pack shall be signed off.
Within 24 hours, Contractor shall bind original charts, and copies of all relevant calibration
certificates together with any other pertinent documentation into the Master Test Pack.
6.4
HYDROSTATIC TESTING
6.4.1
Equipment
The Contractor shall supply and install all necessary equipment and materials necessary to
pressurise and test the pipework and associated equipment.
The equipment, controls, instruments, etc, used in conducting pressure tests shall be in good repair
and of a kind and type acceptable to the Superintendent.
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Continuous pressure and temperature recorders shall be supplied by the Contractor and used to
record pressure and temperature during the test period.
Equipment to be used during testing shall have suitable capacity for the range of test pressures
required. 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 gauges
and chart recorders shall have current calibration certificates endorsed by a NATA approved
authority.
A minimum of two gauges shall be provided for each test system. One shall be located at the
highest point and one located at the pump at grade. A gauge shall also be located at the extremity
of each system unless otherwise agreed by the Superintendent.
6.4.2
Contractor Obligations
The Contractor shall submit comprehensive testing procedures and schedules both for hydrostatic
and pneumatic testing, to the Superintendent for his approval prior to start of testing.
It is the Contractors responsibility to satisfy the Superintendent that procedures will not result in
any damage or deformity to the piping or the equipment and they incorporate all safety
requirements.
Approval of the procedure by the Superintendent does not absolve the Contractor from the
responsibility of workmanship, quality compliance with the Code requirements and safety
considerations.
The Contractor shall review drawings and pipework prior to pressure testing to ensure that
sufficient vents, drains, blind flanges, etc, are installed to carry out the hydrostatic testing
procedures. All high points must be vented and low points capable of being drained. The
Contractor shall provide any additional vents and drains that are required in accordance with the
applicable piping specification.
Any errors, discrepancies or omissions on the drawings shall not relieve the Contractor of the
responsibility for pressure testing the pipework in accordance with the intent of this Standard. Any
such error, discrepancy or omission shall be brought to the attention of the Superintendent for an
interpretation or ruling.
6.4.3
Equipment Isolation
Equipment such as pumps, compressors, blowers, turbines, other rotating machinery and vessels,
heat exchanges, columns, etc, shall be isolated from the pressure test. Spades shall be installed at
the flanges of the equipment to provide positive isolation prior to filling up the system.
Expansion bellows and spring supports shall be restrained or removed during hydrostatic testing.
Each case shall be referred to the Superintendent for direction prior to testing.
All restrictions that would interfere with filling, venting or draining, such as orifice plates and flow
nozzles, shall not be installed until testing is completed. Suitable spacers shall be installed for
testing.
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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 is
not practicable to perform testing prior to installation of inline items, it shall be Contractors
responsibility to remove or disconnect these items so those tests can be performed and to re-install
such items after testing. Sealing and plugging for testing of systems after removal of inline items
shall be performed by contractor. Contractor shall remove sealing and plugging items after
completion 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 be
checked and tested in accordance with ASME B31.3.
All gate, globe and butterfly valves shall be tested in the open position unless otherwise specified
on 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 the
valve and the drain on the downstream side of the valve. Where this is not possible, check valve
internals shall be removed for testing. A new gasket shall be installed if the valve bonnet has been
removed 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. Any
protective tape applied to shop welds in carbon steel spools shall be removed prior to pressure
testing.
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 to
the extent that the valve cannot be operated. If directed by the Superintendent valves shall be
repacked.
6.4.6
Loading Considerations
Care shall be taken to avoid overloading any part of the pipe support system or supporting
structures. Large piping designed for vapour or gas shall be provided with additional temporary
supports, if necessary, to support the weight of the test fluid.
Large adjacent lines shall not be tested simultaneously if the weight of the combined tests may
overload the structure or supports.
6.4.7
Field Installed Reinforcing Pads
The Contractor shall test all field installed reinforcing pads with dry air at 35kPa gauge (5psig).
All weld surfaces shall be swabbed with a leak testing solution approved by the Superintendent.
After testing is complete the vent hole shall be plugged with grease or with approved plastic plugs.
The Contractor shall maintain a record of all reinforcing pad tests.
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6.4.8
Steam Jacketing
The 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 pressurised
to minimise the differential pressure.
6.4.9
Venting
The Contractor shall be responsible for the venting of all sections of the piping system and shall
make 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 at
ambient 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 chloride
content of maximum 1 ppm and pH value between 6 and 7. Water shall be drained immediately
after hydrostatic testing.
A report on water analysis including the chloride content and pH value of the water shall be
attached to the test report at all times when austenitic stainless steel systems are hydrotested. A
certified 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 system
shall be:
a.
1.5 times the design pressure, or
b.
calculated in accordance with formula specified in ASME B31.3 if the design temperature
is above the test temperature.
The test pressure for non-metallic piping shall be in accordance with the piping manufacturers
recommendations and the applicable Australian or international standard covering installation and
testing of the piping material
6.4.12 Test Duration
Pipework shall be observed continuously during all filling and testing operations.
Minimum duration of hydrostatic test from the time the pressure has been obtained with no leaks
shall be:
a.
30 minutes for pipework where:

1.
All sections of the pipe are visible.
2.
The pipe is easy to inspect.
3.
Volume is relatively small.
4.
System of pipework being tested is relatively short and simple.
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b.
c.
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.
As determined and specified by the Superintendent to suit any circumstances but not less
than a or b above.
6.4.13 Rectification
The Contractor shall be responsible for rectification work of damage, resulting from test pressures
being 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 be
recorded.
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 maximum
pressure in the system during the test.
2.
A chart is not recorded as long as the test gauge reading/s are witnessed by the
inspector at the start and the end of the test, and if the duration is longer than 30
minutes, 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 fluid
under, Breaking into Hazardous Pipelines (GM-11-036-02), then the following
dispensations may be considered:
(a)
A standard gauge that has been calibrated within a month of the test may be
used in lieu of a NATA certified gauge. The calibration certificate shall be
included with the test pack in the MDR.
(b)
The requirement for a NATA certified inspector may be waived as long as

the test is witnessed by the Superintendents nominated representative (eg
piping inspector, field supervisor).
4.
For systems with flanges rated up to 300#, where it is difficult to fully spade off the
test system due to factors such as welded in valves and/or lack of available
shutdown time, tests may be done using valves as isolation.
5.
On insulated lines only new, modified or repaired piping, valves and fittings need to
be uninsulated for the test for the purposes of inspection.
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6.5
6.
If parts of a line are not accessible without setting up special access such as
scaffolding, then only new, modified or repaired piping, valves and fittings need to
be made accessible for the test for purposes of inspection.
7.
If the pressure during a hydrostatic test cannot be maintained due to a pre-existing

passing or leaking valve or fitting, or an inability to fully vent the system, then the
test may be passed by continually pumping up the system to test pressure and
inspecting the area of new work for leaks. The Superintendent should perform an
assessment of any leaks from existing valves and fittings to see if maintenance
rectification 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 lines
is not required if CSBP site supplied demineralised water is used.
SYSTEM DRYING
After hydrostatic testing of the system is complete and approved, all lines and equipment shall be
completely drained of the test fluid. Piping systems vents shall be opened while draining to avoid
vacuum. Special attention shall be given to points where water may be trapped, such as in valve
bodies or low points.
An air compressor designed to deliver high volume dry air shall be connected to the system high
point(s). Air shall be blown continuously until all water has been driven out and the
Superintendent accepts the system.
The only exception to this requirement shall be cement-lined pipe, which must be kept in a wet
condition to prevent deterioration of the lining, or if the Superintendent advises that air-drying is
unnecessary. An example of when the Superintendent may advise that air-drying is unnecessary is
when the fluid to flow through the piping is compatible with water, the water is not going to effect
any equipment supplied through the piping, and the line is unlikely to suffer from oxygen/water
corrosion between the test and when it is commissioned (e.g. stainless steel lines, very short time
period 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 performed
where specified by the Superintendent. Where a piping system is to be chemically cleaned it shall
have previously been flushed, tested and blown dry. Drying may be deferred only if chemical
cleaning is to immediately follow a hydrotest.
The Superintendent shall approve any Company undertaking chemical cleaning of pipework.
Unless otherwise specified the chemical solution shall be a solution of Citric Acid and Ammonia.
(Ammonium Citrate degreasing and cleaning solution).
Batch mix a citric acid powder in water to achieve a 3% (weight/volume) solution, adding 0.2%
Surfactant and 0.2% Wetting Agent Detergent. This shall be neutralised with ammonia to a pH of
3 to 3.5, either before putting into the system, or during initial circulation.
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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
Acid Concentration
pH
:
:
:
(Ferrous Iron Pick-up parts per million)

(Percent Weight/Volume)
(Using pH meter)
Iron pick-up will depend upon the condition of the pipework but should fall within a range of 600
to 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 pipe
is as follows:
Ferrous Iron Pick-up
Acid Concentration
Minimum
Optimum
Maximum
Minimum
Optimum
Maximum
600ppm
1500ppm
2500ppm
2% weight/volume
3% weight/volume
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 in
compressed gas and should therefore only be considered when alternative testing procedures can
not 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 accordance
with ASME B31.3 with special consideration given to safety during testing including the setting up
of 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 the
Contractor in liaison with the Superintendent. The procedure shall require final approval by the
Superintendent before being implemented.
Duplicate, high integrity, pressure gauges shall be fitted to the system under test.
6.8
LEAK TESTING OF PIPING SYSTEMS
During the testing stage and just prior to start-up, selected systems such as ammonia, chlorine and
other toxic, flammable and corrosive fluids shall be checked for tightness. Three procedures are
available as follows:
a.
Soap and Bubble Leak Test.
This test is applicable for hazardous fluid systems 600# rating and above.
b.
Nitrogen/Helium Leak 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# and
300# rating. Refer to Section 6.8.8 for details.
The Soap and Bubble Leak test shall be used unless otherwise specified or approved by the
Superintendent.
The systems to be leak tested shall have previously been hydrostatically or pneumatically tested in
accordance with the Code, and therefore all welded joints have been proved sound. The leak test is
limited 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 the
system ready. This procedure should be strictly adhered to.
6.8.2
Workmanship
Contractor personnel and operators of plant and equipment shall be competent, experienced
persons 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 the
Superintendents personnel, including:
a.
opening all inline manually operated valves
b.
opening all inline actuated valves
c.
opening all instrument tapping valves
d.
taping all flanged joints with duct sealing tape and putting pinhole in tape.
e.
identifying purge points and opening vent valves
f.
determining test exclusion zone and erecting suitable barriers.
The Contractor shall set up his equipment and prior to connection to the system fill point(s), shall
blow his manifold and connecting hose(s) to ensure that they are clean.
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A pre test inspection of the system shall be carried out jointly with the Superintendent to ensure
that all preparatory work has been completed, the system is ready to be tested and the test
equipment 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 is
detected.
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 for
leakage 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 done
while 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 test
pressure, 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 or
as directed by the Superintendent, during which time the test gauges shall be closely
monitored. Following this hold period the final check for leaks shall be conducted as
described above.
When all tests are complete, the system shall be de-pressured.

Note:
Pressuring/de-pressuring rate shall not result in a differential pressure of more than 10kPa
across the internals of any vessel within the test; or 100kPa/minute - whichever is the
more stringent.
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6.8.5
Test Records
The Superintendent shall prepare a Test Pack for each system to be tested. Upon successful
completion of each test a certificate contained therein shall be signed by the Contractor and by the
Superintendents 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/Helium
Leak 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 NATA
approved 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 last
tested 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 gas
volumes are maintained.
6.8.9
Simplified Leak test Procedure
Where approved by the Superintendent, the leak test may be simplified as follows:
a.
After the first hold period, the pressure may be slowly taken straight up to the final test
pressure.
b.
Hold at final pressure to be reduced to 30 minutes.
c.
Detection of leaks shall be primarily by visual examination. However a local pressure

gauge or transmitter shall also be used to monitor pressure during the test to look for
evidence of leaks.
d.
No NATA certified test gauges or charts are required.
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e.
A calibrated gauge will be required where the air or nitrogen source could provide
pressures higher than the piping design pressure. This gauge will be used to monitor
pressure 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 there
were 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 Project
specific procedure shall be written by the Contractor in liaison with the Superintendent, in a format
similar to APPENDIX 2. The procedure shall require final approval by the Superintendent before
being 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 shall
ensure 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 sizing
the 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 the
procedure, and upon final completion, reinstate system in accordance with the drawings and as
directed by the Superintendent.
6.9.5
Compressor
This procedure assumes that the Compressor is an integral component in the process stream and is
to be used to provide driving air for the air blowing process. If a temporary unit is brought in to
provide driving air, the company from whom the unit is hired shall provide the pre start-up
checklist.
6.9.5.1
Pre Start-up Checklist
Prior to start-up the following items/systems shall be commissioned and ready for service:
a.
Compressor inlet ductwork,
b.
Any compressor inter-stage pipework has been manually cleaned,
c.
Lube and seal oil systems,
d.
Non-drive motors to be uncoupled,
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e.
Steam supply to turbine from battery limit (also impacted by Steam blowing) if compressor
steam 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 been
completed.
Start up and operation of the compressor shall be in accordance with Manufacturers procedures and
shall be carried out by CSBP personnel, under the supervision of the Manufacturers
Commissioning Engineer.
6.9.7
Control Systems
Control systems for the compressor shall be completed and commissioned such that the compressor
is capable of running under manual control for the purposes of air blowing, however, the control
system shall be available for the compressor and any flow measuring instruments in the systems to
be 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 vessel
flange. In order to achieve correct blowing velocity the gap between flange and target plate must
be adjustable. This can be achieved by employing extra long bolts and additional nuts to capture
and 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 Superintendents 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 air
blows within the schedule without duplication of materials.
Notwithstanding, Contractor shall be responsible for the supply of all materials and consumables
necessary to complete the air-blowing activities in the specified timeframe.
If the Contractor identifies any discrepancies in the materials listed the Superintendent shall be
notified accordingly.
6.10
STEAM BLOWING OF TURBINE PIPEWORK
During the testing stage the lines supplying steam to steam turbines and ancillaries shall be blown
with steam to prove the cleanliness of the system and to prevent potential turbine damage at start-
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up. Steam, shall be blown through the piping system via strategically located exit points, moving
progressively through the plant. A Project specific procedure shall be written by the Contractor in
liaison with the Superintendent in a format similar to APPENDIX 3. The procedure shall require
final approval by the Superintendent before being implemented. The following guidelines shall
apply:
6.10.1 Setting Up
The individual procedure for each Steam Blow shall describe in detail the work required to make
the 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. The
target plate shall then be inspected, and replaced and the system allowed to cool down to 150C.
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 cm2, and
five (5) indentations 0.1mm diameter per 20cm2 .
Stainless Steel Target Plates
A maximum indentation of 0.1mm diameter per cm2, and
five (5) indentations 0.1mm diameter per 20cm2 .
6.10.4 Location of Target Plates

Target plates shall be located as specified in the system narrative; however Contractor shall ensure
that exiting steam flow does not constitute a safety hazard.
Steam Flow Requirements
This shall be in accordance with the turbine manufacturers recommendations, and would typically
be sufficient steam to generate a velocity 1.5 times normal operating velocity. However, the steam
flow may have to be a compromise if there is a limit on steam availability for steam blowing.
6.10.5 Re-instatement
Upon completion of each steam blow, Contractor shall reconfigure system as described in the
procedure and upon final completion; reinstate system in accordance with the drawings and as
directed by the Superintendent.
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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 the
assembly shall be capable of being bolted to the pipe or vessel flange at 45 to the axis of the
flange.
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 Superintendents 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 setting
should be required, however the Manufacturers installation procedure shall be strictly adhered to
and 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 hydrotest
and 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 not
deform 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.
6.12
RE-INSTATEMENT OF PIPING SYSTEMS
Piping systems, which are partially disassembled during testing, re-assembly and re-instatement of
the system, shall be subjected to a final check using the Stage 2 Commissioning Inspection Reports
and reinstatement pack detailed in 6.1.2, to ensure that system integrity has not been compromised.
The P&IDs shall be used in conjunction with isometrics and pipe support drawings to ensure that
reinstatement is complete. See section 6.1.2 on post test punchlisting for checks to be performed
after reinstatement of piping systems.
If Operations personnel have not been involved prior to this point it is recommended that they carry
out or assist in these checks to provide a degree of Plant familiarisation.
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6.13
NITROGEN PURGING
Piping in ammonia and flammable gas service, and any other service specified by the
Superintendent, shall be nitrogen purged after final re-instatement and before commissioning. This
can be combined with leak testing if practical.
Nitrogen shall be fed into the line as close to one end of the piping as practical and vented as close
to the other end as possible. The aim is to purge out as much of the air in the piping system as
possible. If this is not possible, then the system shall be pressurised with nitrogen to approximately
1000 kPag and then depressurised to atmosphere at least 3 times.
Nitrogen purging shall continue until either a specified target oxygen level is reached in the vented
nitrogen, or until the Superintendent advises that the purging can stop.
The Contractor in liaison with the Superintendent shall develop the procedure for nitrogen purging.
The Superintendent shall approve the procedure prior to implementation.
The Contractor will supply nitrogen if it is not available locally.
6.14
PIPING TIE-INS TO EXISTING PLANT
Project specific procedures (both operational and safety) shall be written by the Contractor and
approved by the Superintendent, however interconnection with the existing Plant shall be
progressive during the final phase of Construction as the services are required. As each system is
hooked up the system shall be designated live and identified accordingly.
All work on a live system shall be carried out in accordance with CSBPs permit to work system
(see Work Permit System GM-11-031-51) and applicable safety procedures and guides (in
particular Breaking Into Hazardous Toxic Substance Pipelines GM-11-036-02), and shall be
controlled by the Commissioning Manager.
The Contractor shall include information in his Tool Box Safety Meetings for the construction
workforce regarding identification of live (commissioned) systems during the construction phase.
With the exception of Non Hazardous fluid service piping systems (Category D ASME B31.3),
all tie-in welds which cannot be hydrotested shall be subject to full visual, radiographic and
MPI/dye penetrant examination. Refer to Section 5.1 for non-destructive examination details.
6.15
POST COMMISSIONING CHECKS
The Field Supervisor and / or Plant Operating personnel shall perform a post commissioning in
service leak check. Any leaks detected shall be referred to the Piping Contractor for rectification.
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APPENDIX 1 - FLUID SERVICE PIPING SYSTEM INSPECTION CLASSIFICATION FLOW CHART
Fluid service
to be classified
Non Flammable
Non Toxic
Non Damaging to
Human Tissue
Design Pressure
1035 kPa
Design Temperature
29 to 186C
Metallic Piping
System
Ammonia
Chlorine
Sodium Cyanide
Nitrous Oxide Gas
Non Flammable
Non Toxic
Non Damaging to
Human Tissue
Design Pressure
1035 kPa
Design temperature
29 to 186C
Flammable
Low Level Toxicity
Damaging to Human
Tissue
Design Pressure
> 1035 kPa
Design Temperature
29< or >186C
Non Hazardous
Category D
ASME B31.3
N
Hazardous
Y
Inspection Class
7
Inspection Class
6
Piping Class
600
Y
Inspection Class
5
Class 150
Class 300
Y
Inspection Class
4
Extreme
Toxic
Danger
Severe
Cyclic
Conditions
Hazardous
Y
Inspection Class
3
Non Hazardous
Category D
ASME B31.3
Inspection Class
2
Inspection Class
1
Note
a.
b.
c.
d.
For definition of Severe Cyclic Conditions and Damaging to Human Tissue refer to ASME B31.3.
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 jacketing
fluid 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.
For individual fluid inspection classes refer to CSBP Engineering Standard Basis for Design - Piping (ES-14-601-01).
For details of Inspection Classes refer to Table 1.
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 be
inspected in accordance with Inspection Class 4, NOT class specified against fluid in CSBP Engineering Standard Basis for Design - Piping (ES-14-601-01).
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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 manual
cleaning/inspection between the compressor and the expander as shown on P&IDs 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
HV3201B
300-APR-SB01WR-1010-40P
Line No 1002
R1003
W1521
Line No 1009
Line No 1002
PSV1205
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 target
plate and must be carefully inspected and manually cleaned as necessary to ensure that it contains
no debris prior to Air Blow # 1.
In Line No 1002
1. 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).
In Line No 1009
1. Open HV 3201B.
2. Open bypass valve W 1521.
In Line No 1096
1. Close valve HV 3201A.
In Line No 1015
1. Remove check valve W 1524 and fit temporary spool (DN350 - 150#).
2. Split flanges at K1164 outlet and fit target plate (DN350).
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In Line No 1010
1. Remove HV 1406.
2. Remove FE 1404.
3. Bolt spools B & C together.
4. Remove check valve W 1406 and fit target plate (DN300).
In Line No 1013
1. Shut valve W 1521.
In Line No 1013
1. Remove PSV 1205 and fit blind flange (DN200 - 150#).
In Line No 1013
1. Remove FV 3226 and fit blind flange (DN300 - 150#).
Blow lines in accordance with the approved air blowing procedure.
Material Requirements:
1 x DN200 - 150# RF blind flange c/w gaskets & bolts,

1 x DN300 - 150# RF blind flange c/w gaskets & bolts,
1 x Target plate assembly to suit DN600 - 150# flange,
1 x Temporary spool: (DN350 - 150#) to replace check valve W1524,
1 x DN600 - 150# butterfly valve (W5113).
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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 AN
Plants 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 Acid
Plant.
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 :
TEST PACK No
Process Air
:
311
TEST MEDIUM :
Air
SYSTEM TEST PRESSURE:
850 kPa(g)
2. VESSEL INFORMATION
3.
VESSEL No:
V 1005
TYPE:
Air Filter
TEST PRESSURE :
1254 kPa(g)
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 not
exceed 10kPa.
4. AUTHORISATION
Authorisation is hereby given to conduct a pneumatic test through this vessel at the system
test pressure listed in Section 1 above.
For and on behalf of CSBP LIMITED
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APPENDIX 5 - PIPING TEST PACK INDEX

PIPING TEST PACK INDEX
TEST PACK
NUMBER
TEST
PRESSURE
Version No. 12.0
ASSOCIATED
EQUIPMENT
P&ID
REMARKS
ISSUED TO
CONTRACTOR
RETURNED
FOR
APPROVAL
PRE-TEST
PUNCHLIST
ISSUED
DATE
TESTED
POST-TEST
PUNCHLIST
ISSUED
Page 42 of 44
NUMBER OF
PUNCHLIST
ITEMS
NUMBER
OF ITEMS
COMPLETE
DATE
CLEARED
PUNCHLIST
ITEMS LEFT
OUTSTANDING

ES-14-602-02
APPENDIX 6 - INSPECTION & TEST LOG BOOK

INSPECTION & TEST LOG BOOK
---- This Section to be completed by Contractor ---Date
Test #
Version No. 12.0
Hydro or
Pneumatic
Date & Time of Test
----This Section to be completed by CSBP---Name
Assigned
Inspector
Complete &
Accepted
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Remarks

ES-14-602-02
APPENDIX 7 - PIPING FIELD TEST REPORT

PIPING FIELD TEST REPORT
Service:
Priority System No.:
Facility:
Piping Test No.:
Plant Location:
Test Pressure:
Test Pack Accepted By:
CSBP SUPERINTENDENT
Test Media:
LINE NUMBER
ISOMETRIC
NUMBER
P&ID NUMBER
FROM
CSBP AUTHORISATION TO PROCEED WITH PRESSURE TESTING
TO
DATE:
REMARKS
PRESSURE TESTING WITNESSED BY:
PIPING / MECHANICAL ENGINEER
NAME
DATE
FOR CONTRACTOR
NAME
DATE
FABRICATION INSPECTOR
NAME
DATE
FOR CSBP
NAME
DATE
Version No. 12.0
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Inspection and Testing of Piping Systems

This is a Controlled Document that complies with

INSPECTION AND TESTING OF PIPING SYSTEMS

Reasons for Creating

Actual Change Details:

Control Block updated; New Authoriser - Manoj Thakur; No

Full Review of Document

DEFINITION OF TERMS ................................................................................................................ 3

QUALITY SYSTEMS .......................................................................................................................... 7

QUALITY PLANS ............................................................................................................................ 7

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Document last modified: 25 January 2013. PDF created: 06 February 2013.

Inspection and Testing of Piping Systems

DESIGN REVIEW .......................................................................................................................... 10

NON DESTRUCTIVE EXAMINATION - PIPING AND FITTINGS ........................................... 13

PUNCHLISTING PIPING SYSTEMS ........................................................................................... 17

APPENDIX 1 - FLUID SERVICE PIPING SYSTEM INSPECTION CLASSIFICATION FLOW

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Document last modified: 25 January 2013. PDF created: 06 February 2013.

Inspection and Testing of Piping Systems

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Document last modified: 25 January 2013. PDF created: 06 February 2013.

Inspection and Testing of Piping Systems

APPLICABLE CODES AND STANDARDS

Manufacturers Standardisation Society of the Valve and Fittings Industry (MSS)

g. Standards Association of Australia (SAA)

CSBP ENGINEERING STANDARDS AND PROCEDURES

Insulation of Piping and Equipment

Basis for Design - Piping

Fabrication and Installation of Piping

Piping Material Specifications

Valve Specifications for Process Isolation

Engineering Project Design Review.

Manufacturers Data Report (MDR) Plant Projects

CSBP GUIDE MANUALS

Take 5 and Job Safety Analysis Risk Assessment

CSBP STANDARD FORMS

Stage 1 Commissioning Inspection Reports

Stage 2 Commissioning Test Reports

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Inspection and Testing of Piping Systems

AMERICAN SOCIETY FOR TESTING AND MATERIALS

Welded and Seamless Steel Pipe

Seamless Carbon Steel Pipe for High Temperature Service

Alloy - Steel and Stainless Steel Bolting Materials

Seamless & Welded Austenitic Stainless Steel Pipes

Seamless & Welded Steel Pipe for Low-Temperature Service

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

Wrought Austenitic Stainless Steel Piping Fittings

AMERICAN PETROLEUM INSTITUTE

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

Fire Test for Valves

Wafer and Wafer-Lug Check Valves

Steel Venturi Gate Valves

Valve Inspection and Testing

Metal Plug Valves - Flanged and Welding Ends

Steel Gate Valves, Flanged and Buttwelding Ends

Compact Steel Gate Valves

Fire Test for Soft-Seated Quarter-Turn Valves

Lug and Wafer Type Butterfly Valves

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Document last modified: 25 January 2013. PDF created: 06 February 2013.