PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
LSTK PACKAGE-B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
PROCEDURE FOR PRESSURE TESTING OF PIPING SYSTEM
PDRP271-8440-PR-6029
LSTK Package-B, Paradip Refinery
Project
Project Name
Owner
: Indian Oil Corporation Limited (IOCL)
PMC
: Foster Wheeler
LSTK Contractor
: Punj Lloyd Ltd.
Contact No
: 271/4200
Contact No
: 1-14-4200/4399
O3
04, MAY 2012
Issued for
Comments
Sharad
Shukla
(Engineer-QC)
S C Gupta
(ManagerQA/QC)
O2
09,APRIL 2012
Issued for
Comments
Sharad
Shukla
(Engineer-QC)
S C Gupta
(ManagerQA/QC)
O1
24,Jan 2012
Issued for
Comments
Sharad
Shukla
(Engineer-QC)
S C Gupta
(ManagerQA/QC)
Rev
Date
Purpose of Issue
Prepared By
(PLL)
Checked By
(PLL)
Approved BY
(FW/IOCL)
Page 1 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
TABLE OF CONTENTS
1.0 PURPOSE............................................................................................................ 3
2.0 SCOPE............................................................................................................... 3
3.0 REFERENCE DOCUMENTS..............................................................................3
4.0 RESPONSIBILITIES...........................................................................................3
5.0 METHODOLOGY...............................................................................................4
6.0 HEALTH, SAFETY RISK ASSESSMENT............................................................8
7.0 QUALITY ASSURANCE & QUALITY CONTROL...............................................9
8.0
APPENDICES/FORMATS..................................................................................9
Page 2 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
1.0
PURPOSE
The purpose of this document is to adopt proper methodology to carry out the safe
Pressure testing of piping and pipe systems.
2.0
SCOPE
This document covers detailed method statement for Pressure testing of Piping and Pipe
systems.
3.0
REFERENCES
ASME B 31. 3, 2010 Edition- Process Piping.
ASME B 31. 1, 2007 Edition- Power Piping.
IBR Regulations
Line List
PDRP4200-8820-SP-1002 Standard Specification for Pressure Testing
4.0
RESPONSIBILITIES
Project Manager
- Shall report to Head of SBU-PLL
Shall be responsible for providing resources for the
implementation of this procedure.
- Shall report to the Project Manager.
Resident Construction
- Ensure Compliance to project specifications
Manager
Fulfill all required safety measures
Provide adequate resources for execution of work
shall report to RCM,
-
Site Construction
Engineers
- Shall be responsible for day to day planning of site
construction
activities
and
preparation
of
construction records.
- Shall be responsible for implementation of All
Piping Hydrotesting activity as per this procedure.
Monitored and implement all identified control
Page 3 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
- Responsible to monitor & ensure the quality of work
is in accordance with this procedure.
Site QC In-Charge
Shall Report to RCM,
Shall be responsible for report non-compliance to
- the concern supervisor and ensure rectifications
prior to the next process activity.
Prepare report and compile record books.
Safety Officer
Shall report to EHS Manager and responsible for
monitoring
safety
performances
and
where
necessary initiating corrective action through line
management.
5.0 METHODOLOGY
5.1 PROCEDURE
i.
Pressure testing of piping systems and integral components shall be done in strict
accordance with the contract specifications, codes, standards.
ii.
Test pack diagrams shall be prepared from the P & IDs, Isometrics showing the
extent of the piping / pipe line under test.
iii.
Preparation of field test packages :
Test packages containing the following records/ reports / documents shall be
prepared.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Test Pack Index.
P & IDs.
Drawing Index.
Isometrics.
Line List.
Line History sheet.
Check List for Piping works.
Punch list (pre test).
Release for pressure test.
Pressure test record.
Page 4 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
k)
l)
m)
n)
o)
Post test reinstatement record.
Post test activities completion record.
Punch list (Post test).
Calibration Certificate of Pressure Gauges
Calibration Certificate of Pressure Relief Valve in case of Pneumatic Test
Test Limits, Test Blind and test flange shall be marked in P&ID and Isometric
drawings.
5.2 TEST PREPARATION.
5.2.1 Before Pressure Test, the lines shall be checked as per the P & ID and
Isometric that the line are complete in all respects and are in fact ready for
test as given in the P & ID. Prior to Pressure test system shall be flushed.
5.2.2 It should be checked that the pressure source and check valve should be
up stream of check valve. If pressure source is downstream, the flapper of
the check valve is removed, taken out for hydrotest and is clearly indicated.
5.2.3 Test blinds & Spades will be same rating as that of existing class are of
correct thickness and are properly identified to ensure their removal after
testing.
5.2.4 All the items such as control valves, relief valves, diaphragms, expansion
joints shall be removed and tagged and same shall be installed after hydro
testing.
5.2.5 Equipment such as filters whose internals could be damaged during testing
are either blocked or removed.
5.2.6 All the temporary supports required for Sole Hydro test purpose as
indicated in the Test Pack diagrams shall be checked for their installation.
Proper care shall be taken for their removal after test.
5.2.7 Equipment such as compressors, Pumps, which are not included in the test,
shall be properly isolated with the Blind Flange.
5.2.8 Test should not be conducted against closed valve.
5.2.9 Proper installation of High point vents and Low point drains to be checked.
5.2.10 Access shall be provided for all weld joints for inspection for leaks.
5.2.11 The water quality shall be checked for maximum allowable limit of 50 PPM
of chloride content while testing stainless steel piping.
Page 5 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
5.2.12 All the deficiencies found during the pretest are listed, prioritized in the
punch list and a copy of the same is given to construction department for
rectification.
5.2.13 All Category A items in the punch list shall be cleared, signed off by
construction, QC and FW / IOCL before commencement of hydrotest.
5.2.14 Line shall be cleaned and flushed prior to hydrotest.
5.2.15 Once the punch list is signed off, hydrotest clearance shall be obtained from
the client by the pressure testing coordinator.
5.3
TESTING
5.3.1 The Pressure test gauge which is calibrated and possessing valid
calibration certificate shall be used.
5.3.2 Stickers are put on each pressure gauge, which indicates Serial No.
Calibration date and calibration due date.
5.3.3 One pressure gauge shall be located at the Hydrotest manifold so that care
can be taken that the system is not pressurized beyond the test pressure.
The other pressure gauge may be located at the high point of the system.
5.3.4 Asbestos free gasket shall be used for hydrotest purpose.
5.3.5 In the case of hydrotest the pressure shall be increased in stages and at the
end of each stage the pressure is held for at least 10 minutes for the
stabilization of pressure inside the pipe. Care should be taken that the
system is not pressurized beyond the test pressure. The pressure shall be
held for 15 min or sufficient time to allow any leak detection of the system.
5.3.6 In case of Pneumatic testing, initially the pressure is increased to one half
of the test pressure or 1.7 bar (25-Psig) whichever is less and the joints are
tested for leaks using soap solution. If no leak is found than the pressure is
increased in steps of 1bar g (15-Psig) until the pressure reaches the test
pressure. The pressure is held at least for 10minutes and the joints are
checked for leakage. Now the pressure is released to 90% of the test
pressure and the joints are once again checked for leakage using soap
solution. Now the pressure is brought to test pressure and held for sufficient
time to allow any leak detection of the system
5.3.7 The test pressure for hydro test is normally 1.5 times the design pressure
and that of the pneumatic testing is 1.1 times of the design pressure.
Hydrotest test pressure shall be mentioned in the line designation table and
minimum two pressure gauges shall be provided in the system.
Page 6 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
5.3.8 Leaks found shall be marked and be visible from the adjacent platform the
pressure shall be released, the medium of test shall be drained or vented
and the repair work shall be carried out after duly informing the client. After
carrying out the repair the system shall be cleared for re testing.
5.4
TEST COMPLETION
5.4.1 Upon completion of the test both PLL & FW/IOCL shall sign off the pressure
test record.
5.4.2 The system is now drained taking care that all the vents are open with plugs
and blinds flanges removed.
5.4.3 Chemical cleaning where required shall be performed after the hydrostatic
testing.
5.4.4 After drainage, remove all the temporary blinds and blanks, temporary
supports and testing connections.
5.4.5 All items removed shall be reinstated after the test. Care shall be taken that
the gasket and the bolts as mentioned in the specification are used.
5.4.6 Upon completion of post testing activities, the post testing activity
completion form shall be signed off by PLL & FW/IOCL and all the
documents as mentioned in the clause 6.1.3 shall be submitted to the client.
5.4.7 After hydrotest completion if nitrogen purging is required as per the
specification shall be carried out.
5.5
LIST OF PROPOSED PLANT/EQUIPMENTS AND MANPOWER LIKELY TO BE
DEPLOYED AT WORKPLACE
5.5.1 Plant/Equipment
i)
v)
Filling Pumps
(5Hp)
Pressurizing Pump (250 Kgf)
Compressor (450 CFM)
High Pressure Compressor
Pressure gauges
- 02 Nos.
- 01 No.
- 03 Nos.
- 01 No.
- 10 Nos.
i)
ii)
iii)
iv)
5.5.2 Man power
Execution in-charge
Engineer
QA/QC Engineer
Safety Engineer
- 01 No.
- 01 Nos.
- 01 Nos.
- 01 No.
ii)
iii)
iv)
Page 7 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
v)
vi)
vii)
viii)
ix)
xiv)
XV)
6.0
Supervisor
Welder
Gas Cutter
Rigger
Helper
Electrician / Mechanic
Pump Operator
- 02 Nos.
- 01 Nos.
- 01 Nos.
- 05 Nos.
- 05 Nos.
- 01 Nos.
- 01 Nos
HEALTH, SAFETY RISK ASSESSMENT.
6.1 Work briefing using the risk assessment / method statement before work starts. The
completed pre-work briefing copy shall be forwarded to the safety department. The
original pre-work briefing shall always be kept by the team leader of each work group
and shall be produced upon demand. All staff of the Pressure testing team shall have
a brief introduction on piping pressure testing. An induction shall be carried out to all
supervisory staff prior to start of Pressure testing activity. Isolate the area with
barrication tape and put the sign board pressure Test Under Progress
6.2 All equipment shall be inspected at three monthly intervals and recorded and shall be
colour coded. All involved shall wear PPE.
6.3 Only competent personnel are permitted to operate equipment and such persons shall
be tested by a competent person and issued with an Appointment Certificate
authorizing them to operate said equipment.
6.4 The Construction Manger shall immediately correct any hazards observed or reported
to him. In the case of major hazards work shall be stopped and appropriate action to
remove the hazard shall be taken. Where permanent corrective action cannot be
achieved immediately it shall be done before the expiry of one working shift.
6.5 The composition of method statements / risk assessments will review/assess,
equipment, materials and the environmental aspects of the proposed work. Such
method statements / risk assessments shall always be referred to sub-contractor /
contractor safety departments for review and comment.
6.6 Ensure that an emergency /rescue plan to cater for any mishap (injury, fire etc.) is
incorporated in the induction program.
6.7 Where incidents / accidents occur the site supervisor shall contact Construction
Manager who shall immediately report the matter to the safety department. Verbal
reports shall be confirmed in writing within one hour of the occurrence. Qualified
personnel shall give proper first aid and medical care immediately to injured persons.
Preserve the scene of the incident/accident until such time as authorization is given
by FW/IOCL to continue work.
Page 8 of 9
PROCEDURE FOR PRESSURE TESTING OF PIPING
SYSTEM
LSTK PACKAGE B, PARADIP REFINERY PROJECT
LOCATION: PARADIP, ORISSA STATE, INDIA
Contract No. : 271/4200
PDRP271-8440-PR-6029 REV O3
6.8 Good housekeeping shall be maintained at all times. Hygiene and welfare facilities
such as toilets, hand washing measures, drinking water, and canteen shelter, food
waste bin/s and defined smoking area will be available.
6.9 In Case of Pneumatic test safety relief valve shall be provide in the Test line.
7.0
QUALITY ASSURANCE & QUALITY CONTROL
This shall be followed and maintained with the compliance / adherence to the method
statement, Inspection Test Plan and by keeping records in the relevant check-sheet and
formats.
8.0
APPENDICES
Appendix-01 Test Pack Formats.
Page 9 of 9
