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NIOEC-SP-50-05(0)

DOCUMENT CODE NO. OF PAGES: 44


PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG PI SP 5005 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY


NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

FIELD PRESSURE TESTING

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
JULY, 2005 NIOEC-SP-50-05(0)
JULY, 2005 NIOEC-SP-50-05(0)
REVISION INDEX
REV. REV. REV. REV.
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
PAGE PAGE PAGE PAGE

1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

1
0 JULY, 2005 M.KHEZRI A.NAVARCHI M.R.FARZAM M.A.A.SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
JULY, 2005 NIOEC-SP-50-05(0)

CONTENTS: PAGE NO.

1. SCOPE 3

2. REFERENCES 3

3. UNITS 4

4. DEFINITIONS & TRMINOLOGY 4

5. GENERAL REQUIREMENT 4

6. HYDROSTATIC PRESSURE TESTING FOR PLANT PIPING SYSTEM 5

6.1 General 5
6.2 Testing Area 6
6.3 Test Equipment 7
6.4 Test Medium 7
6.5 Test Pressures 8
6.6 Nonmetallic Piping-Test Pressure 9
6.7 Test Duration 9
6.8 Test Preparation 9
6.9 Procedure for Hydrostatic Pressure Test 11
6.10 Measures to be Taken after Hydrostatic Testing 12
6.11 Leaking Welds 12

7. PNEUMATIC PRESSURE TESTING 12

7.1 General 12
7.2 Test Equipment 13
7.3 Test Medium 13
7.4 Pneumatic Test Pressure 13
7.5 Precautions to be Taken in Pneumatic Pressure Testing 13
7.6 Pneumatic Testing Procedure 14

8. MANUFACTURING CERTIFICATE FOR FABRICATED PIPING 14

9. PRESSURE TESSTING THROUGH EQUIPMENT 14

9.1 Heaters and Furnaces 14


9.2 Unfired Pressure Vessels 15
9.3 Heat Exchangers 15
9.4 Storage Tanks 16
9.5 Safety and Relief Valves 17
9.6 Pumps, Turbines, Blowers and Compressors 17
9.7 Miscellaneous Equipment 17

10. PRESSURE TESTING OF INSTRUMENTS 17

11. TEST RECORD 18

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CONTENTS: PAGE NO.

12. APPENDIX 1 (Guide for piping pressure test activities and compilation of
Pressure test package documents) 19

12.0 Scope 19
12.1 Documentation 19
12.2 Preparation of Test Package 19
12.3 Test Scheduling 20
12.4 Line Checking 20
12.5 Preparation for Line Check and Hydrotest 22
12.6 Line Cleaning 22
12.7 Pressure Test 22
12.8 Post Test Activities & Restoration 24
12.9 Final Test Package Documents 24

ATTACH. A Type of Pressure Testing 25

ATTACH. B(1/2) Piping Test Package (TP) Flow Chart 26

ATTACH. B(2/2) Detail Work Flow for A/G. Test Package Document
Handling/ Line Checking/ Pressure Test/ Post Test 27

ATTACH. C Test Package Documents (Sample File) 28

ATTACH. D Recommended Pressure Gauge Range 44

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1. SCOPE

This Specification covers the minimum requirements of field pressure test to be carried
out on plant piping system, equipment (Heaters and furnaces, unfired pressure vessels,
Heat exchangers, storage tanks) and instruments, upon completion of construction work
and before commissioning.
The test is required in order to prove the strength of system, its tightness (absence of
leaks) and the integrity of weldments and materials.

2. REFERENCES

Throughout this Specification the following dated and undated standards/ codes are
referred to. These referenced documents shall, to the extent specified herein, form a part
of this Specification.
For undated references, the latest edition of the referenced document (including any
supplements and amendments) applies. For dated references, the edition cited applies.
The applicability of changes in dated references that occur after the cited date shall
mutually be agreed upon by NIOEC and the Vendor/Contractor.

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERING)

ASME B 31.3 – 2004 “Process Piping”


ASME B 31.1 “Power Piping”
ASME B 31.5 “Refrigeration Piping”
ASME B 16.5 “Steel Pipe flanges and flanged fittings”

API (AMERICAN PETROLEUM INSTITUTE)

API 650 “Welded steel tanks for oil storage”

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-00-02 “NIOEC Specification for site Preparation-Earth


Work and Sewers”
NIOEC-SP-41-03 “NIOEC Specification for Pressure Vessels”
NIOEC-SP-44-01 “NIOEC Specification for Shell & Tube Heat
Exchanger”
NIOEC-SP-45-03 “NIOEC Specification for Fired Heaters”
NIOEC-SP-50-07 “NIOEC Specification for Cleaning and Protection
of Piping"
NIOEC-SP-50-17 “NIOEC Specification for Protection of Under
Ground Steel Pipe”

NIOEC STANDARD DRAWINGS

NIOEC-SD-5044-1/1 “Hydro Static Test Blind”

IPS (Iranian Petroleum Standards)

IPS-E-GN-100 “Engineering Standards for Units”

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IPS-C-IN-100 “Construction and Inspection Standard for General
Instrument and Testing of Instrument and
Instrument System”

3. UNITS

International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.

4. DEFINITIONS AND TERMINOLOGY

4.1 Employer: Means National Iranian Oil Engineering and Construction Company
(NIOEC).

4.2 Contractor: Means EP contractor or EPC contractor.

4.3 Construction contractor: Construction Contractor is the party which carries out all as
part of construction and/or commissioning for the project.

4.4 Inspector: The Inspector is a person/persons or a body appointed in writing by the


Engineer for the inspection and testing.

4.5 Engineer: The Engineer is a person or a body appointed in writing by the Employer.

4.6 Owner Representative: Refiner representative introduced in writing to the Engineer.

5. GENERAL REQUIREMENTS

5.1 In addition to the requirements specified in this NIOEC Specification


, piping systems shall be tested in accordance with the provisions of ASME code as
follows:
a) For process and general utility services ASME B.31.3.
b) For piping within the scope of steam generation ASME B.31.1.
c) For refrigeration piping system ASME B.31.5.

5.2 For field pressure testing of pressure vessel, heat exchangers, heaters, storage tanks
and underground piping systems, in addition to the stated requirements in related
sections of this NIOEC Specification, referenced codes & standards as specified, and
manufacturer’s recommendation shall be considered.

5.3 Care shall be taken to ensure that the following equipment is not subjected to field
pressure test:

a) Pumps, turbines and compressors.


b) Rupture discs, safety valves, flame arrestors, filter elements.
c) Instruments, including gage glasses and pressure gages.
d) Equipment where the internal lining may be damaged by the test
medium.
e) Equipment such as filters and driers where the content could be damaged
or contaminated.
f) Vessels and exchangers which have hydrostatic test pressure less than the
line test pressure.

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6. HYDROSTATIC PRESSURE TESTING FOR PALNT PIPING SYSTEM

6.1 General

6.1.1 Before commencing pressure test, the construction contractor shall be provided
with the following latest approved for construction document for review and
compilation of test package documents and execution of the test, who shall
then prepare a detailed test procedure and submit to Contractor / Employer
for approval.
a) Pressure test flow diagram.
b) Test block list.
c) Field pressure testing (this NIOEC Specification).
d) Any other information as necessary.

Note: As a guide, procedure for pressure test activities of plant piping


systems (including preparation of test package documents, TP
flowchart, line checking, line cleaning, hydrotest, post test activities
and restoration, final test package documents) in line with this
NIOEC Specification is given in APPENDIX 1.

6.1.2 For convenience, vessels may be tested simultaneously with connected piping
provided that requirements as stated in 6.1.3 & 6.1.4 below are met. Vessels
shall not be tested with the piping when the following conditions exist:
a) Large vessels which would overload the foundation or support if filled
with water.
b) Large vessels requiring too much water to fill.
c) Vessels with internals which would be damaged by water.
d) Vessels which are extremely difficult to drain or vent.

6.1.3 Where the test pressure of piping attached to a vessel is the same as or less than
the test pressure for the vessel, the piping may be tested with the vessel at the
piping test pressure.

6.1.4 Where the test pressure of the piping exceeds the vessel test pressure, and it is
not considered practicable to isolate the piping from the vessel, the piping and
the vessel may be tested together at the vessel test pressure, provided that
employer, with the consent of owner, approves and the vessel test pressure is
not less than 77% of the piping test pressure calculated by equation 1. (See
6.5.1)

6.1.5 If a portion of a piping system can not be hydrostatically tested because the
presence of water is objectionable, a notation shall be made on the pressure test
flow sheets indicating that hydrostatic testing by water is prohibited.

6.1.6 Underground lines inside plot limits shall be completely tested, inspected,
drained and approved before backfilling of the lines are carried out.(See
NIOEC-SP-50-17 and NIOEC-SP-00-02)

6.1.7 Cast iron piping with spigot and socket joints shall be intermittently covered,
leaving the joints clear and all the bends securely anchored before testing.

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6.1.8 Vents shall be provided at all high points in the piping system and drains shall
be provided at all low points.

6.1.9 Fabrication and welding shall be complete prior to system testing.

6.1.10 Welding cleanup, nondestructive examination, stress-relieving, and other heat


treatments shall be completed before pressure testing is performed.

6.1.11 Insulation shall not be applied over welded or mechanical joints and
connections. Screweds or welds shall not be painted before pressure testing.

6.1.12 Testing shall be performed by qualified personnel of construction contractor


who are thoroughly familiar with all equipment and test procedures.

6.1.13 Pressure testing shall be performed in presence of the Employer inspector.

6.1.14 Pressure testing should be performed when the weather condition is suitable
for inspection.

6.1.15 Pressure relief and thermal expansion relief valves shall be excluded from the
general pressure tests. Blinds shall be installed immediately adjacent to their
inlet and outlet (if required) flanges during tests. Relief valve test gags may
be used in place of blinds. Screwed relief valves shall be removed and the
connections temporarily plugged or capped during the tests.

6.1.16 Lines containing check valves shall have the source of pressure located in the
piping upstream of the check valve so that pressure is applied under the seat.
If this is not possible, the check valve flapper shall be removed or jacked up.

6.1.17 Seats of valves shall not be subjected to a pressure in excess of the maximum
cold working pressure of the valve.

6.1.18 Short pieces of piping which must be removed to permit installation of blind
or blank, should be tested separately.

6.1.19 Pipe supports and anchors should be fitted prior to pressure testing. In certain
cases temporary or additional supporting of pipe work may be required due to
weight of the testing medium.

6.1.20 For permanent flanged joints, permanent service gaskets shall be used. For
temporary flanged joints, test gasket shall be used. Record of such temporary
gaskets, shall be maintained.

6.2 Testing Area

6.2.1 If possible, test equipment including pumps, gages, recorders, and other items
shall be located in the same area.

6.2.2 The area shall be continuously monitored by test personnel while testing is
being performed so that any change in test procedures or conditions will be
noted immediately and corrective action taken as required.

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6.3 Test Equipment

The inspector approval shall be obtained prior to use of equipment intended for the
execution of the pressure test.

6.3.1 Instruments
The required instruments for each test shall be as follows:

a) Pressure gage, accurate to within 1% of its range. The range shall be 1.5
to maximum 2 times of test pressure.
b) Dead weight tester and temperature indicator, if specified, instruments
shall be suitably protected from all elements. Prior to testing, they shall
be calibrated (preferably on site) and a record of the instrument
calibration and identification shall be kept as part of the inspection
records. The calibration date and identification should be affixed to the
instruments. Calibration shall be done according to IPS-C-IN-100.

6.3.2 Pumps
Construction contractor shall be responsible for the supply of suitable pumps
for the testing. As a minimum a high volume centrifugal pump for filling and a
variable speed positive displacement reciprocating pump with sufficient
discharge head and capacity for the pressurization shall be provided.
The construction contractor shall provide chemical injection pump and means
necessary for measuring of the inhibitor (if required) to be added to test water.

6.4 Test Medium

6.4.1 The test fluid normally shall be fresh water and shall not contain suspended
solids which may plug small lines. If it is found necessary water filter shall be
used equipped with 100 mesh screen to remove 99% of particles which are
140 microns or more in size.

6.4.2 The water shall have a corrosion inhibitor if so specified on the pressure test
flow sheets.

6.4.3 If the water temperature is likely to fall to zero degrees Centigrade or below,
glycol or another antifreeze approved by the Engineer shall be added.

6.4.4 Carbon and low-alloy steel


Piping manufactured from carbon steel or low-alloy steel may be
hydrostatically tested with fresh water. Brackish or sea water may be used
provided that prior approval of the Engineer is obtained.

6.4.5 Stainless steels


The chloride content in the water used for the hydrostatic testing of piping
manufactured from or containing parts manufactured from austenitic stainless
steel (e.g., 18 Cr- 8 Ni or 18 Cr-10 Ni-2 Mo), shall be less than 40PPM.,
laboratory test report shall be provided.

6.4.6 Duplex stainless steels


The preferred method is to use condensate or demineralized water (up to 2
PPM chloride).

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6.4.7 9% Nickel alloy steel
The test water shall be of a neutral PH value, clear and free from sulfides which
may otherwise precipitate stress cracking of the equipment.

6.4.8 In systems where residual moisture can not be tolerated, e.g., in SO2, acid,
ammonia and LPG service and where certain catalysts are used, other test
medium shall be selected. If flammable liquid is used consideration shall be
given to the test environment.

6.5 Test Pressures

6.5.1 General process piping-test pressure


The hydrostatic test pressure, at any point in a metallic piping system shall be
as follows:
a) Not less than 1.5 times of the design pressure.

b) For design temperature above the test temperature the minimum test
pressure shall be calculated by the following formula, except that the
value of ST/S shall not exceed 6.5:

1.5 PST
PT = (Eq.1)
S
Where:
PT = Minimum hydrostatic test pressure
P = Internal design gage pressure
ST = Allowable stress at test temperature
S = Allowable stress at design temperature
(See table A-1 ASME B31.3)

c) If the test pressure as defined above would produce a stress in excess of


the yield strength at test temperature, the test pressure may be reduced to
the maximum pressure that will not exceed the yield strength at test
temperature. (All code requirements as mentioned in ASME B 31.3 shall
be considered)

d) Where the pipe work being tested contains flanges, the test pressure as
determined in paragraph 6.5.1 (b) for piping should be in accordance with
section 8 of steel pipe flanged fittings, ASME B 16.5.

6.5.2 Refrigeration service-test pressure


Refrigerant piping shall be tested in accordance with the provisions of ASME
B31.5 "Refrigeration Piping" and be successfully dried out accordingly, or
other measures approved by the Engineer shall be applied against freezing.

Note:
However no oxygen or any combustible gas or combustible mixture of
gases shall be used for testing within the system. Water should not, if
possible, be used for testing of refrigerant piping, but if used, it must be
completely removed as described in paragraph 6.10.5.

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6.5.3 Vacuum service-test pressure


Lines in vacuum service shall be tested at a minimum internal pressure of 200
kPa (29 psi) unless limited to a lower pressure by design and/or construction.

6.5.4 Utilities service-test pressure


The test pressure for service air and water piping shall be 1½ times the design
pressure or 700 kPa (100 psi) for steel piping, whichever is higher. Flanged
cast iron piping shall be tested to 1½ times the design Pressure + Maximum
static head of pipe content during operation; but in no case more than the
following test pressures:

Size (Dia.) Class 125 Flange Class 250 Flange


DN 25-300 (NPS 1-12) 1700 KP (250 psi) 3500 KP (500 psi)
DN 350-600 (NPS 14-24) 1400 KP (200 psi) 2800 KP (400 psi)
DN 750 (NPS 30 & LARGER) 700 KP (100 psi) 1400 KP (200 psi)

6.5.5 Jacketed lines-test pressure


In jacketed lines the jacket shall be tested in accordance with paragraph 6.5.1
on the basis of jacket design pressure. The internal line shall be tested on basis
of external or internal design pressure whichever is greater, unless limited by
the engineering design conditions. Limitations shall be noted on the pressure
test flow diagram.

6.6 Nonmetallic Piping-Test Pressure

The hydrostatic test pressure at any point in a nonmetallic piping system shall be not
less than 1.5 times the design pressure, but shall not exceed 1.5 times the maximum
rated pressure of the lowest rated component in the system.

6.7 Test Duration

The test pressure shall be maintained for an adequate time (not less than one hour) to
detect small and slow seepage leaks and to permit a thorough inspection.

6.8 Test Preparation

6.8.1 For hydrostatic testing, all pipe supports shall be in position and completed
before testing is undertaken.

6.8.2 All piping intended for other than liquid service shall be adequately supported
by temporary supports if necessary, particularly on lines using spring or
counterweight supports. Large adjacent lines shall not be tested simultaneously
where the weight of the combined test water load may overload the structure
of supports.

6.8.3 If blind flanges are necessary, the flanges shall be indicated on the pressure test
flow diagrams.

6.8.4 All lines should be cleared of debris by flushing with water or blowing with
steam or air. Precautions should be taken to ensure that debris is not flushed
into associated vessels, equipment or "dead ends".

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6.8.5 The construction contractor of test shall consider temporary gaskets when
making connections that will be broken for testing or reassembly after testing.

6.8.6 Ball valves and gate valves shall be completely open during the test.

6.8.7 The construction contractor shall take care to avoid contaminating valve seats
with foreign particles.

6.8.8 Lines containing check valves shall have the pressure source located on the
upstream side. If impossible, the check valves shall be removed from the line
or blocked open.

6.8.9 Lines which have spring hangers or are counterweight supported shall be
temporarily blocked up during testing in order to sustain the weight of the test
fluid. Sometimes spring hangers are provided with stops for carrying the test
load and need not be blocked up.

6.8.10 All orifice plates shall be removed before the test.

6.8.11 Equipment that is not to be included in the test shall be isolated by blinds or
shall be disconnected from the piping.

6.8.12 Control valves shall remain in the line for testing. Those which are normally
closed shall be opened by clean dry air. The valves shall not be jacked or
forced open.

6.8.13 Pressure control valves with internal passages between the process fluid and
the diaphragm shall be isolated from the test. External connections shall be
disconnected or blocked during the test. The diaphragm pressure shall be bled
off.

6.8.14 Expansion joints of the sliding sleeve or bellows type should be provided with
temporary means to limit lateral movement.

6.8.15 Expansion joints, instruments, filters and similar equipment for which the
maximum permissible cold test pressure is considerably lower than the
maximum hydrostatic test pressure permissible for the other components of
the system shall be removed or blanked off from the line before testing. Such
equipment should be inspected during the commissioning with due regard to
the pressure limitation.

6.8.16 Plugs shall be removed from tell-tale holes in compensating rings and
reinforcement pads around branches (nozzles) and the holes left open during
hydrostatic testing and observed for any leakage.

6.8.17 Prior to commencement of the test a thorough check shall be made to ensure
all fittings, flanges, plugs, etc., are in place. All flanges and flanged fittings
shall be bolted and bolts properly torqued.

6.8.18 Testing of more than one individual section simultaneously may be carried
out by connecting the sections with suitable jumper lines. The materials used

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in the fabrication of these jumpers shall be of the same quality as the system
under test, as a minimum. Threaded piping shall be minimized on jumper
lines.

6.8.19 Instrument piping at orifice flanges shall be removed or a drain or vent shall
be opened to ensure that the instrument does not become pressurized because
of a leaking valve.

6.8.20 Mounted instrumentation shall be isolated from the system during testing.

6.8.21The supply connection size shall ensure filling of the system within a
reasonable time, and it shall have a flanged valve.

6.8.22 A valve shall be used for depressurizing, for which a globe valve is preferred.

6.9 Procedure for Hydrostatic Pressure Test

6.9.1 Pressure test sections shall be chosen by the construction contractor, based on
the submitted approved pressure test flow diagram, test block list and testing as
much piping as possible at one time without exceeding the allowable test
pressure of the weakest element in the system.

6.9.2 Vents and other connections that can serve as vents shall be open during filling
so that all air is vented prior to the application of test pressure to the system.

6.9.3 Test pressures shall be taken at the lowest point of a line or test system.

6.9.4 During hydrostatic testing, care must be exercised to limit the applied pressure
to the particular portion of the system designated on the field pressure test flow
diagram.

6.9.5 Care must also be taken to avoid overloading any parts of supporting
structures.

6.9.6 Where conditions require a test pressure to be maintained for a period of time,
during which the test medium in the system might be subject to thermal
expansion, provision shall be made for the relief of excess pressure due thereto.
(By either installation of a proper relief valve or discharging excess pressure.)

6.9.7 Test pressure shall not be applied against any closed valve unless the maximum
allowable working pressure (MAWP) of the valve exceeds the test pressure.

6.9.8 If the test pressure is the same upstream and downstream of a control valve, the
block and by-pass valves shall be left open, with the control valve open or
closed (whichever is most convenient).

6.9.9 If the test pressure is different at upstream and downstream of a control valve,
the test on the upstream portion shall be made with the upstream block valve
and control valve open, downstream block valve and by-pass valve open and
blinded off.

6.9.10 All plain test blanks required for field testing shall be provided and/or made in
the field according to NOEC-SD-50-01.

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6.10 Measures to be Taken after Hydrostatic Testing

6.10.1 After hydrostatic testing is completed and approved by the inspector, the
system shall be depressurized.

6.10.2 After depressurizing, lines and equipment shall be completely drained. The
equipment should be cleaned, if necessary (in the opinion of the inspector).

6.10.3 While draining, the system shall be vented to avoid a vacuum.

6.10.4 Special attention shall be given to points where water may be trapped such as
valve bodies or low points.

6.10.5 Systems shall be dried after draining. The drying process may be
accomplished by blowing warm compressed air through the system or by
another method approved by the Engineer.

6.10.6 All temporary blanks and blinds shall be removed. Valves, orifice plates,
expansion joints and short pieces of piping which have been removed shall be
reinstalled with proper and undamaged gaskets in place. Valves which were
closed solely for hydrostatic testing shall be opened. Temporary piping
supports shall be removed so that insulation and painting may be completed.

6.11 Leaking Welds

Welds or portions of welds that leak during hydrostatic test shall be cut out,
rewelded, radio graphed and line shall be hydrostatically tested again at the
construction contractor’s, expense.

7. PNEUMATIC PRESSURE TESTING

7.1 General

With prior approval by the Engineer pneumatic testing may be substituted for
hydrostatic testing if the following conditions apply. Pneumatic test should be
specified in pressure test flow sheet when it is substituted for hydrostatic testing.

a) When special supports or other special arrangements would be required on large, low-
pressure lines.
b) When hydrostatic tests are uneconomical or impractical.
c) When the possibility exists that piping, insulation, refractory material, or attached
equipment might be damaged by water.
d) When even a small amount of water left in a system, such as a refrigerant system,
could be injurious.

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7.1.1 The following lines are usually excluded from hydrostatic testing, and are
usually tested with compressed air and soap suds:
a) Instrument air lines (test with dry air).
b) Air lines to air-operated valves. (Test with dry air only).
c) Very large (usually over DN 600-NPS 24) gas or steam overhead line.
d) Pressure parts of instruments in gas or vapor service.

7.1.2 If investigation determines that testing is required for relief or blow down
header systems or individual pipe stacks more than 15.2 m in height which are
open to atmosphere, they need only be tested for tightness with soap suds at 0.4
bars (5psi) air pressure.

7.1.3 Piping with linings subject to damage by water, shall be tested with other
suitable test medium. (This shall have been specified in test flow diagram &
test block last.)

7.1.4 Lines over DN 200 (NPS 8) from tank tops will be air tested in order to
minimize excessive loads, and/or the need for special designed supports or
foundations.

7.2 Test Equipment

7.2.1 Instrument
See Clause 6.3.1 of this Standard.

7.2.2 Compressors:
a) The construction contractor shall be responsible for the supply of suitable
compressors for the testing.
b) Air compressors with oil lubricated construction shall not be used for purging
and testing instrument air lines.

7.3 Test Medium

7.3.1 Unless otherwise specified, pneumatic testing shall be performed with clean
dry air or nitrogen.

7.3.2 Air for instrument air lines shall be oil-free.

7.3.3 If other gases are used as a test medium, it shall be nonflammable and
nontoxic.

7.4 Pneumatic Test Pressure

The pneumatic test pressure of any piping system shall be equal to 110% of the
design pressure of the system. If the test pressure exceeds 150 psig written approval
of the Engineer shall be obtained.

7.5 Precautions to be Taken in Pneumatic Pressure Testing

7.5.1 Due to the large energy stored in compressed gas and, hence, the potential
hazard of a sudden release of this energy, pneumatic testing shall be carried out
in small sections to minimize the risk involved.

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7.5.2 A pressure relief device shall be provided, having a set pressure not higher than
the test pressure plus the lesser of 345 Kpa (50 Psi) or 10% of the test pressure.

7.5.3 The possibility of brittle fracture shall be considered when conducting tests at
metal temperatures near the ductile-brittle transition temperature.

7.5.4 Flange joints shall be masked with tape. One small hole shall be punched in the
tape to indicate leaks.

7.5.5 Welds of piping subjected to pneumatic strength test above 150 psig shall be
100% radio graphed.

7.5.6 In view of its hazardous nature, pneumatic pressure test shall only be
undertaken with the presence of the Employer’s inspector.

7.5.7 All non-essential personnel and members of the public, when necessary, shall
be evacuated from the test area.

7.6 Pneumatic Testing Procedure

The following steps shall be taken in performing pneumatic test:

a) Gradually bring piping system pressure up to the lesser of one-half the test
pressure or 100 kPa (gauge), 14.5 psig, and make a preliminary inspection.
Carry out a leak test using a sonic detector or soapy water. Hold pressure for at
least 10 minutes.
b) The test pressure shall be increased gradually in increments of the lesser of one-
half the test pressure or 100 kPa (14.5 psig) maximum to provide time for
stress in the piping to equalize.
c) When the full test pressure has been reached, the pressure shall be held for a
sufficient time and then be reduced to the design pressure before examining for
leaks.
d) The pressure shall be gradually reduced to atmospheric at the end of the test.

8. MANUFACTURING CERTIFICATE FOR FABRICATED PIPING

The Engineer shall make sure that prefabricated piping which are not included in the
pressure test is certified by an inspectorate authority.

9. PRESSURE TESTING THROUGH EQUIPMENT

9.1 Heaters and Furnaces

Extreme care shall be taken in field testing of heater and furnace tubes, which are
normally field fabricated and must be hydrostatically tested. Where possible, piping
and heater tubes shall be tested together.
Heater tubes shall be tested to manufacturer’s recommended test pressure. Test shall
be coordinated with heater erection subcontractor.
Requirements specified in NIOEC-SP-45-3 shall also be considered.

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JULY, 2005 NIOEC-SP-50-05(0)

9.2 Unfired Pressure Vessels

9.2.1 Vessel constructed in accordance with ASME Code Section VIII will not
require individual pressure tests at site except in the following cases: (See also
NIOEC-SP-41-03.)

a) Vessels whose condition, resulting from transport, storage, handling, or for


any other cause is suspect in the opinion of the Employer’s inspector.
b) Vessels which have had any site fabrication / modification which in the
opinion of the inspector necessitate a site pressure test.

9.2.2 Pressure testing of vessels will be carried out in the presence of the Employer’s
inspector.

9.2.3 With the exception of relief valves, all valves and fittings should be installed
on the vessels and included in the test. Relief Valves must be removed or
otherwise isolated.

9.2.4 All plugs should be removed from tell tale holes in reinforcing pads before the
test pressure is applied.

9.2.5 Provision should be made for the venting of air from the test system.

9.2.6 No insulation, paint or other covering may be applied over any welded seam
before completion of the test.

9.2.7 For individual pressure tests of vessels, as may be required by paragraph 9.2.1,
the hydrostatic test pressure will be indicated on vessels’ nameplate.

9.2.8 In the case of vessels so designed that they cannot support a full head of water,
or where the foundations impose a weight limitation, a combined hydrostatic
and pneumatic test may be necessary. The procedure in such cases shall be in
accordance with requirements of ASME code section VIII Div. 1 or 2 as
applicable and must be submitted for Employer’s approval.

9.2.9 Base level checks on large volume vessels, columns and spherical tanks if
required, should be taken on each supporting column during filling and
emptying with water.

9.2.10 On satisfactory completion of a pressure test the vessel should be drained


completely, any blinds inserted for test purposes removed and these joints
remade to the satisfaction of the Employer’s inspector.

9.3 Heat Exchangers

9.3.1Provided manufacturers test certificates are available, only the following


pressure tests should be carried out on heat exchangers except as required by
paragraph 9.3.2.

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JULY, 2005 NIOEC-SP-50-05(0)

a) On floating head shell and tube type exchangers, a leak test on shell and
tube side separately shall be carried out at test pressure of 1½ times the
maximum. Operating pressure (corrected for service temperature) of each
side while testing each side, all vents and drains of other side shall be kept
open. And no parts need to be removed. If any sign of leakage or pressure
drop detected, then the test shall be repeated with appropriate parts
removed to investigate the source of leakage and taking remedial action.

Note (1): Care shall be taken to limit the test pressure to proper amount for
exchangers designed on differential pressure basis.
Note (2): Provision of adequate number of spare gaskets shall be foreseen
in advance.

b) On tube-in-tube type, on both sides, separately, in conjunction with


associated pipe work and the test pressure should be on for the associated
pipe work.
c) On air-cooled types, the bundles are to be isolated and tested separately
from associated pipe work. Test pressure shall be 1½ times the maximum
operating pressure corrected for maximum operating temperature.

9.3.2 In the case of tubular exchangers whose condition, resulting from transport or
other causes, is suspect in the opinion of the Employer’s inspector, a pressure
test on the suspect side at the maximum allowable pressure should be carried
out. Tests may be carried out individually or on groups of exchangers having
similar operating conditions. Special precautions are required when exchanger
tube sheets are designed for differential pressure less than shell and/or tube side
design pressure. (See also 9.3.1 (a) note 1)

9.3.3 After completion of test all equipment must be thoroughly drained and if
necessary, dried out to prevent scaling of tubes before commissioning.

9.3.4 After completion of test all bonnets and covers should be replaced, temporary
blanks removed and all joints remade to the satisfaction of the inspector. All
compressed fiber gaskets shall be renewed.

9.3.5 NIOEC-SP-44-01, NIOEC Specification for shell and tube heat exchanger shall
also be considered.

9.4 Storage Tanks

9.4.1 All tanks shall have bottoms, shells and roofs tested in accordance with API
Standard 650. Shells shall be tested by filling tanks with water. Vacuum testing
shall be used for all tank bottoms and roofs.

9.4.2 Floating roofs shall be tested by the following methods:

a) Center deck plates, pontoon bottom plates and rim plates with welded joints
shall be sprayed with light gas oil on the bottom side and inspected
visually on the top side and inside of rim plates.

16
JULY, 2005 NIOEC-SP-50-05(0)
b) Each completed compartment of pontoon roofs shall be individually tested
with air pressure of 75 MM (3 inches of water gauge). A soapy water
mixture shall be applied to all welded joints under pressure.
c) Roof drains together with any flexible couplings incorporated with them
shall be subjected to a hydrostatic test pressure of 3.5 bars (50 psig) with
the tank empty prior to this test the drain piping should be flushed through
to ensure the absence of any internal obstruction.

9.5 Safety and Relief Valves

9.5.1 The blow off (set) and blow down (re-set) pressure of all relief valves should
be set to the specified figures on P&ID & S.V, data sheets and to the
satisfaction of the inspector and the owner representative.

9.5.2 When settings are finally approved the owner representative will fix a seal to
each valve.

9.5.3 On removal from the testing ring after pressure setting, the inlet and outlet
branches of all relief valves should be covered to prevent ingress of dirt, etc.
These covers should not be removed until a relief valve is being installed.

9.5.4 The Employer’s inspector and the owner representative will check each valve
after it has been re-installed to ensure that its seal is intact.

9.5.5 In case where the valve exhausts to a pressure system, the downstream side
should be tested to a pressure equal to the test pressure rating of the outlet
system.

9.5.6 Inlet lines to relief valves should be cleared before valves are finally installed.

9.6 Pumps, Turbines, Blowers and Compressors

These shall not be subjected to hydrostatic test in the field.

9.7 Miscellaneous Equipment

Expansion joints shall be provided with temporary restraint if required for additional
pressure load under test, or shall be isolated from the test. Isolate from test if
allowable test pressure is not known. Flame arrestors, filters, and other
miscellaneous equipment that does not have test pressure indicated shall be isolated
from the test.

10. PRESSURE TESTING OF INSTRUMENTS

10.1 Certain types of instruments with their connecting process lead lines shall be tested
at the same pressure as the main pipe lines or the equipment to which they are
connected. Such instruments normally include the following types:

17
JULY, 2005 NIOEC-SP-50-05(0)

Displacer Type Level


Instruments Control Valves

Gauge Glasses Flow Meter Pots

Rotameters

10.2 Other types of instruments shall not be tested at line pressure, but shall have
process lead lines tested to the first block valve or valves nearest the instrument.
Care shall be taken that this equipment is protected by removal, or by blocking the
instrument lead line and disconnecting or venting the instruments. These types will
normally include the following:

Analyzers Diaphragm Type Level Instruments

Differential Pressure Type Direct Connected


Flow Instruments Regulators

In-line Type Flow Switches Open-Float Type Level Indicators


And Alarm Switches

Positive Displacement Type Pressure-Balanced


Flow Meters Control valves

Pressure Indicators Recorders Pressure Gauges


and Transmitters

Pressure Switches Turbine Type Flow Sensors

10.3 Special precautions shall be taken to insure that instruments and instrument lead
lines to be tested are vented and completely filled before testing, and are
thoroughly drained after test.

10.4 Hydrostatic testing of instruments and instrument piping shall be coordinated with
the instrument erection subcontractor.

11. TEST RECORD DOCUMENTS

Test procedures, documents, reports and test results (one original + 1 copy) shall be
submitted to employer on completion of tests and prior to stat up of unit. Test record
documents shall be as follows:

11.1 Piping installation

Test record documents shall include the following completed and signed final
documents/ reports which are prepared gradually as the fabrication/ erection
activities progresses and finally compiled as “Test Package Documents”. (Original
+ 1 Copy shall be submitted to Employer)
(See Appendix 1)
a) Test package content.
b) Piping test package cover sheet.

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JULY, 2005 NIOEC-SP-50-05(0)
c) Marked up test flow diagram to show test circuit and test block list.
d) As built Iso drawing or/and QC (Quality Control) Iso drawings with bill of
materials.
e) Piping spool shop fabricated inspection report. (if applicable).
f) NDT/PWHT completion report.
g) Line checks report.
h) Punch list (prepared by construction contractor).
i) Punch list (prepared by contractor/ employer as applicable).
j) Pad test report, as required.
k) Orifice flange inspection report as required.
l) Inspection report for line cleaning.
m) Pressure gauge calibration report.
n) Test medium laboratory test report, as required.
o) Pressure test report.
p) Post test inspection and restoration report.

11.2 Equipment

Records shall be made of each equipment during test which includes:


a) Date and time of test.
b) Identification of the equipment being tested.
c) Test medium used, with laboratory test report, as required.
d) Test pressure.
e) Approved by construction contractor/ contractor and employer and owner
inspector (as required). Original + 1 Copy shall be submitted to the Employer.

12. APPENDIX 1 (Guide for Piping Pressure Test Activities and Compilation of Test
Package Document)

12.0 Scope

As a guide, this procedure covers pressure test activities of piping system including
preparation and compilation of test package documents, TP flow chart, line
checking, line cleaning, hydrotest, post test activities and restoration, final test
package documents in line with this NIOEC Specification.

12.1 Documentation

Prior to the test Employer/ Contractor will provide for Construction Contractor the
following latest approved construction documents for review and compilation of
the test package document and execution of the test.
a) Pressure test flow diagrams.
b) The block list for process unit.
c) Field pressure testing specification.
d) Any other information as necessary.

12.2 Preparation of Test Packages

After completion of installation and preparation of scaffolding Construction


Contractor shall proceed with preparation of test package document for each test
section and submit these to Employer/ Contractor 3 weeks prior to the test.

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JULY, 2005 NIOEC-SP-50-05(0)
The test package documents shall include the following information inserted in
relevant columns and signed by Construction Contractor.

a) Test package contents


b) Piping test package cover sheet
c) Marked up test flow diagram to show test circuit and test block list
d) As built Iso drawing or/and QC Iso drawings with bill of materials
e) Piping spool shop fabricated inspection report
f) NDT/PWHT completion report
g) Line check report
h) Punch list – A (A1 for welding, A2 mechanical) prepared by Construction
Contractor
i) Punch list – B (B1 for welding, B2 for mechanical) prepared by
Employer/ Contractor
j) Pad test report as required
k) Orifice flange inspection report as required
l) Inspection report for line cleaning
m) Pressure gauge calibration report
n) Pressure test report
o) Post test inspection and restoration report

The test package will be reviewed by Employer/ Contractor and then return it to
Construction Contractor.

12.3 Test Scheduling

Construction Contractor will prepare test schedule in coordination with Contractor


on a weekly basis. Test schedule shall include due dates for different stages of test
preparation, i.e., line checking punch listing, rectification of punch items,
preparation and execution of line cleaning test, dry out and restoration. Copies of
test schedule shall be distributed by Construction Contractor to the relevant parties.

12.4 Line Checking by Contractor, Employer and Construction Contractor

NOTE:
Line checking may be executed jointly or separately, as agreed, however
Construction Contractor shall proceed his initial line checking & rectifies
all deficiencies prior to requesting Employer/ Contractor for line checking.
All mechanical / functional line checking as shown below is normally
performed and related punch list would be prepared and issued to
Construction Contractor within one week.
Construction Contractor shall provide suitable access/platforms for
thorough inspection of lines before submission of test package which
remain up to the end of hydrotest completion and restoration. Rectification
of punch items will be followed and finally the related punch list forms and
line check report will be signed by concerned parties.

A: Mechanical line check after erection.

A.1 Conformity of installed line configuration with piping plan, ISO drawings and P&ID:
1.1 Location / Dimension / Elevation of piping.
1.2 Verticality / Levelness / Straightness.

20
JULY, 2005 NIOEC-SP-50-05(0)
1.3 Line Slope Per drawing.
1.4 Reducers Type and Location.
1.5 Installation of Orifice Flange.

A.2 Conformity of materials with ISO drawings bill of material:


2.1 Line size.
2.2 Pipe and fittings material.
2.3 Bolt tension (if specified) and correct length.

A.3 Branches:
3.1 Branches located correctly.
3.2 Type of branch is in accordance to NIOEC Specification for piping material
NIOEC-SP-50-04.
3.3 Branch reinforcement pad and weep holes.
3.4 Gussets installed, where required.

A.4 Gasket installation:


4.1 Type, material, thickness.

A.5 Conformity of pipe supports with isometric drawings and removal of temporary
supports:
5.1 Anchors installed.
5.2 Guides installed.
5.3 Proper shoes installed and welded.
5.4 Spring hangers / supports and their block pins, installation and correctness of
item code number.

A.6 NDT check:


6.1 Welding completed and all NDT (RT, PT, MT, and Hardness) requirements
have been completed satisfactorily and records are available.
6.2 Post weld heat treatment (if any) have been done satisfactorily and records
are available.
6.3 Final inspection of the line and weldment for possible damages, weld spatter,
arc strikes, and any other deficiencies.

B: Functional line checking:

1. Conformity to all requirements in latest P&ID.


2. Requirement of operational drain / vent.
3. Operability.
4. Accessibility / maintenance.
5. Readable requirements of instruments.
6. Checking of Supports, stoppers, guides, including cold offset setting from
thermal stress view point.
7. Spring hanger / support installation and settings.
8. Other general piping engineering matters.

Punch item which do not require line modification / cutting / welding and have no
effect on pressure testing, may be rectified at later stage. Construction contractor
shall provide the list of such items and their estimated completion date.

21
JULY, 2005 NIOEC-SP-50-05(0)

12.5 Preparation for Line Cleaning and Hydrotest

1.Line cleaning / water flushing procedure and pressure test procedure (identifying
cleaning method, test equipment, facilities, pressurizing rate, safety precaution,
location of gauges, point(s) of filling and drainage, vents, etc, marked up on test
flow diagram) shall be submitted by Construction Contractor to Contractor and
Employer for review and acceptance.

Note: Some lines such as seal oil/ lube oil, compressors suction line, etc. require
chemical cleaning. Such chemical cleaning shall be done after completion
of normal cleaning, hydrotest and prior to start up as per NIOEC-SP-50-
07.

2.For pneumatic test, separate procedure with safety precaution consideration as


required in ASME B31.3 and this NIOEC Specification shall be prepared and
submitted for review and acceptance.

3.Preparation for line cleaning and hydrotest will be checked by Contractor and
Employer’s inspector, and then punch list(s) (if any) will be issued.
Construction Contractor shall notify Contractor and Employer by issuing
application for inspection, both for line cleaning and pressure test date.

12.6 Line Cleaning

1. Precaution should be taken to ensure that debris is not flushing into vessels,
equipment, pumps, etc., while executing line cleaning / flushing.

2. During cleaning / flushing stage, parts such as PSV, control valves, thermo
wells, strainer element, orifice plates, and all instruments shall not be installed
or somehow exempted. When pre-test cleaning / flushing is completed, control
valve, thermo well, strainer element, level instrument, and expansion joints of
sliding sleeves* shall be installed and included in the test as required.
* For expansion joint Employer and Contractor confirmation required.

3. Line cleaning / Water flushing shall be witnessed by Contractor and Employer


and the corresponding report shall be prepared and signed.

12.7 Pressure Test

Requirements of this NIOEC Specification shall be strictly followed. All pressure


testing will be witnessed by Contractor and Employer inspector and upon
satisfactory completion of the test, the pressure test report will be signed by
concerned parties.
Checking prior and during test are not limited to those described below
requirements of field pressure testing specification shall be followed, however,
following check items are highlighted as guidelines only:

22
JULY, 2005 NIOEC-SP-50-05(0)

1.Verify chloride content and PH of test water prior to release of water to


Construction Contractor for testing of austenitic stainless steel lines or
components (maximum chloride content shall not exceed 40 PPM; laboratory test
report is required.)

2.Pressure source and gauge shall be upstream of check valves, if pressure source
is down stream, check valve should have flapper removed or jacked up. Pressure
must be released downstream the check valve after test completion.

3.Where soft seated ball valves are in line and located at the end of test section, the
pressure side of the line at ball valve flange shall be blinded, if such ball valve is
within the line being tested it shall be in the fully open position.

4.If the test pressure is the same upstream and downstream of a control valve, the
block and by-pass valves shall be left open, with the control valve in open or
closed position.

5.If the test pressure is different at upstream and down stream of a control valve,
the test on the upper stream portion shall be made with the upstream block valve
and control valve open. Down stream block valve and by-pass valve open and
blinded off.

6.Seats of valves shall not be subjected to a pressure in excess of the maximum


cold working pressure of the valve.

7.For permanent flanged joints, permanent service gasket shall be used, for other
temporary flanged joints test gasket shall be used. Record of such temporary
gaskets shall be maintained.

8.Test blinds shall be of correct thickness with handle painted red, a record should
be kept showing the location of test blinds to ensure their removal at the test
completion.

9.Verify location of test gauges and suitability of the pressure gauge range and its
division (Range should be 1.5 to a maximum of 2 times of the test pressure and
accuracy of division to be 1%). See attached table

10. The test gauges shall be calibrated and calibration certificate available.

11. Pipe supports and anchors shall be fitted prior to pressure testing.
Additional supporting of pipe work may be required due to weight of testing
medium.

12. When conditions require that a pressure test be maintained for a period of time
during which the testing medium in the system would be subject to thermal
expansion, provision should be made for relief of excess pressure.

13. During hydrotesting, care must be exercised to limit the applied pressure to the
particular portion of the system designated on the field pressure test flow
diagram.

23
JULY, 2005 NIOEC-SP-50-05(0)
14. Short pieces of piping which must be removed to permit installation of blind or
blank should be tested separately.

15. Each test shall be held for 60 minutes without any loss of pressure prior to
requesting inspector to witness the test.

12.8 Post Test Activities and Restoration

After completion of hydrotesting, followings to be executed:

1. All lines shall be completely drained; care shall be exercised in controlling the
rate of water drain in respect to inflow of air through the vents to ensure that
vacuum is not applied.
CAUTION: Prior to commencing drainage, ensure that all vents are open with
plugs and blind flanges removed.

2. Remove all temporary blanks and blinds.

3. Dry out austenitic stainless steel lines and other carbon steel piping where acid
forming process could be involved.

4. Remove temporary supports and temporary testing connection.

5. Remove temporary gaskets for hydraulic test and install proper service gaskets.

6. All piping components shall be reinstalled except the followings:

Orifice plates.
PSV.
Instrument component (such as PG restriction orifice, etc.).

Spring hanger set pin or spring support stop pin shall not be removed.

12.9 Final Test Package Documents

Records shall be made of the completed and signed final test package documents
(listed in item 12.2).
Original of final test package documents plus one copy shall be submitted to
Employer.

24
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT A (1/1)
NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY REPORT NO.:
JOB NO.
PROJECT: SH… OF…
……………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
TYPE OF PIPING PRESSURE TESTING
APPLIED (As
TEST TYPE TEST MEDIUMS per Test Block WORK SEQUENCE
Dia.)

HYDROSTATIC Water General CASE-1 Line Press.


* For SS/HA piping (Base Case) cleaning Test
Max. Cl. 40 ppm Line Dry out Restoration
CASE-2 checks/
(When app. Punch out Press. Line
by NIOEC) Test cleaning

PNEUMATIC Air Large Dia Piping CASE-1 Air Press.


* Oil free air for IA - Air line (Base Case) blowing Test
to air-operated - Flare Line Restoration
valves and N2 for - Gas CASE-2 checks/
unit 02 (When app. Punch out Press. Air
by NIOEC) Test blowing

IN SERVICE Service Fluid Only Approved


Line checks/ Flushing/ Service
by NIOEC
Punch out Blowing test Restoration

Note for line cleaning

For large diameter piping hand wipe/ sweep should be applied as much as possible (inspection to be recorded).

25
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT B (1/2)
NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY REPORT NO.:
JOB NO.
PROJECT: SH… OF…
……………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING TEST PACKAGE (TP) FLOW CHART
EXECUTION
(PUNCH OUT/ DOCUMENTATIO
LINE N (FINAL
REVIEW / LINE CHECK / PUNCH LIST RECORD
CLEANING/ DOCUMENT
PRESS. TEST/ CONFIRMATION)
POST TEST)

- Review -line check -Witness - Confirm


EMPLOYER - Confirm - Signature
(NIOEC) - Punch list
- Signature on orig. TP

Working copy
- Review -Witness - Confirm TP Copy
QC Gr. QC items - Confirm - Signature
- Punch list - Signature on orig. TP Keep by contractor
(&NIOEC)
CONTRACTOR
-line check
-Review - Punch list -Witness - Confirm
Piping Gr. -Register -Review - Confirm - Signature
- Signature on orig. TP
Working copy
TP Copy TP Original
-Execution - Confirm
CONST. - Confirm - Signature
CONTRACTOR - Signature on orig. TP Keep by CC
TP Original & finally submit
to NIOEC
Keep by CC

- CC will prepare original TP and one copy for working LEGEND:


Working copy TP flow
REMARKS
Original TP flow
Original TP (*) working copy TP flow

26
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT B (2/2)
NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY REPORT NO.:
JOB NO.
PROJECT: SH… OF…
……………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
DETAIL WORK FLOW FOR A/G TEST PACKAGE DOCUMENT HANDLING/
LINE CLEANING/ PRESS. TEST/ POST TEST
ACTIVITY TEST PACKAGE LINE CHECK NIOEC/CONTRACTOR/PUNCH OUT LINE CLEANING PRESS. TEST POST TEST
Three Weeks
TIME/PERIOD One Week Immediately after testing
Before Testing

- Line check Confirmation Witness Witness Check Copy of


EMPLOYER - QC document of test pack.
(NIOEC) review Punch out
- Punch list

- Line check Confirmation Witness Witness Check Copy of


- QC document of test pack.
CONTRACTOR review Punch out Two Copies
- Punch list
Notice No Ok
Notice No Ok

-Preparation Line -Preparation Line -Drain out Post Test (R)*


Test Follow up of line cleaning of line cleaning -(Drying) - Finalize test
CONST. Package Punch Item cleaning (R)* cleaning (R)* - Restoration package
CONTRACTOR preparation - Application - Application - Application

* (R) – Inspection record required.

TEST PACKAGE : NOT TO INSTALL INSTALLATION REMOVE


- PSV - Control valve - Temporary blind
- Contents – Refer to “Test Package Contents” - Control valve - Thermwell - Other temp. part
- Thermwell - Strainer element INSTALLATION
- Strainer element - Level Instrument - Expansion joint (Note 1)
REMARKS
- Orifice plate - Expansion joint (Note 1) NOT TO INSTALL
- All instruments - PSV
- Disconnect all inst. - Orifice plate
- Lead piping
- Expansion joint (Note 1) * Spring Hanger set pin do not remove

Note 1: NIOEC / Contractor conformation is required.

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JULY, 2005 NIOEC-SP-50-05(0)

ATTACHMENT C (1/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.

TEST PACKAGE CONTENS


TEST PACKAGE NO.: DATE

TEST BLOCK NO.: PREP

1 TEST PACK CONTROL SHEET


2 PIPING TEST PACKAGE COVER SHEET
3 TEST BLOCK LIST
4 MARKED UP TEST FLOW DIAGRAM TO SHOW TEST CIRCUIT
5 AS BUILT ISO DRAWING OR/AND/Q/C ISO DRAWING WITH
BILL OF MATERIAL
6 PIPING SPOOL SHOP FAB. INSPECTION REPORT
7 NDT/PWHT/WELD HISTORY (LINE HISTORY SHEET)
8 PUNCH LIST (A1,A2)
9 PUNCH LIST (B1,B2)
10 A/G PIPING CHECK LIST
11 PAD TEST REPORT (IF ANY)
12 ORIFICE FLANGE INSPECTION REPORT (IF ANY)
13 PRE-PRESSURE TEST LINE CLEANING
14 PRESSURE GAUGE CALIBRATION RECORD.
15 PIPING PRESSURE TEST REPORT
16 POST TEST & RESTORATION INSPECTION REPORT

28
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (2/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
TEST PACK CONTROL SHEET TEST PACK No.:
1ST ISSUE: RECEIVED FROM CC PRE TEST WORK
COMPLETED
RECIPIENT DATE SIGNATURE ACCEPT SIGNATURE DATE REJECT DATE REMARK
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE

ISSUE 2: RECEIVED FROM CC PRE TEST WORK


COMPLETED
RECIPIENT DATE SIGNATURE ACCEPT SIGNATURE DATE REJECT DATE
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE

ISSUE 3: RECEIVED FROM CC PRE TEST WORK


COMPLETED
RECIPIENT DATE SIGNATURE ACCEPT SIGNATURE DATE REJECT DATE
CONTRACTOR
MECHANICAL
CONTRACTOR
PIPING
CONTRACTOR
WELDING
NIOEC
NOTE

THIS TEST PACK HAS BEEN COMPLETED AND ALL PUNCH LIST ITEMS SIGNED OFF AND ACCEPTED AND READY
FOR HYDROSTATIC TESTING
CONS. CONTRACTOR CONTRACTOR NIOEC

SIGN. DATE SIGN. DATE SIGN. DATE

29
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (3/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.

PIPING TEST PACKAGE COVER SHEET


TEST PACKAGE DESIGN PRESS.
No.
TEST BLOCK No. TEST PRESS.
AREA/UNIT TEST FLUID.
P&ID DWG No.
PLAN DWG No.
ITEM LINE NO. ISO. NO. SHT. NO.

INSPECTION / CONFIRMATION SUMMARY

DESCRIPTION C.C. CONTRACTOR NIOEC


NAME/SIGN/ NAME/SIGN/ NAME/SIGN/DATE
DATE DATE
TEST BLOCK LIST
MARKED UP TEST FLOW DIAGRAM TO SHOW TEST CIRCUIT
AS BUILT ISO DRAWING OR/AND/Q/C ISO DRAWING WITH
BILL OF MATERIAL
PIPING SPOOL SHOP FAB. INSPECTION REPORT (RELEASE)
NDT/PWHT/WELD HISTORY REPORT
PUNCH LIST (A1,A2)
PUNCH LIST (B1,B2)
A/G PIPING CHECK LIST
PAD TEST REPORT (IF ANY)
ORIFICE FLANGE INSPECTION REPORT (IF ANY)
PRE PRESSURE TEST LINE CLEANING
PRESSURE GAGE CALIBRATION RECORD
PIPING PRESSURE TEST REPORT
POST TEST INSPECTION AND RESTORATION REPORT

30
JULY, 2005 NIOEC-SP-50-05(0)

ATTACHMENT C (4/16)

1- TEST BLOCK LIST

TEST FLOW SHEET

2- ISO DRAWINGS & BILL OF MATERIAL

(Item 1 & 2 above appropriate for each test package shall be attached)

31
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (5/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING PUNCH LIST – A1 (WELDING)
TEST PACKAGE:
NO. ISO DWG NO. LINE NO. DESCRIPTION OF CORRECTION REQURED COMPLETED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONSTRUCTION CONTRACTOR CONTRACTOR NIOEC

SIGN DATE SIGN DATE SIGN DATE

32
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (6/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING PUNCH LIST – A2 (MECH.)
TEST PACKAGE:
NO. ISO DWG LINE NO. DESCRIPTION OF CORRECTION REQURED COMPLETED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONSTRUCTION CONTRACTOR CONTRACTOR NIOEC

SIGN DATE SIGN DATE SIGN DATE

33
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (7/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING PUNCH LIST – B1 (WELDING)
TEST PACKAGE:
NO. ISO DWG LINE NO. DESCRIPTION OF CORRECTION REQURED COMPLETED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONSTRUCTION CONTRACTOR CONTRACTOR NIOEC

SIGN DATE SIGN DATE SIGN DATE

34
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (8/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING PUNCH LIST – B2 (MECH.)
TEST PACKAGE:
NO. ISO DWG LINE NO. DESCRIPTION OF CORRECTION REQURED COMPLETED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

REMARK:

CONTRUCTION CONTRACTOR CONTRACTOR NIOEC

SIGN DATE SIGN DATE SIGN DATE

35
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (9/16)
NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY REPORT NO.:
JOB NO.
PROJECT: SH… OF…
……………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING SPOOLS SHOP FABRICATED
ISO DRG NO: INSPECTION REPORT
SPOOL NO: Release Report LINE NO:
CONS.
NO CHECK ITEMS CONTRACTOR NIOEC REMARKS
CONT.
1 CONFORMITY WITH ISO DRG (CONFIGURATION, DIMENSIONS, SIZE,…)
2 PIPE MATERIAL & THIKNESS. CORRECT
3 FLANGE MATERIAL & RATING. CORRECT
4 TYPE & MATERIAL OF FITTINGS, VALVES & OTHER COMPONENTS (if any) CORRECT
5 WELDING COMPLETED, VISUALLY INSPECTED. EXT. & INT (if possible) & ACCEPTED
6 NDE (RT,PT,MT) COMPLETED AND RESULTS STATIS FACTORY
7 PWHT AND HARDNESS TEST COMPLETED SATIS FACTORILY
8 OLETS FOR INSTRUMENTS CONNECTIONS CORRECTLY INSTALLED (LOCATION &
ORIENTATION)
9 INSTRUMENT FLANGES TO PIPE WELDED JOINTS ARE INTERNALLY FLUSHED.
(SMOOTHED)
10 INTERNAL PARTS OF VALVES & OTHER COMPONENTS PRONE TO DAMAGE WERE
REMOVED BEFORE WELDING OR OTHERWISE PROPERLY PROTECTED.
11 VISUAL INSPECTION OF SPOOL FOR DAMAGE (SPECIALLY FLANGE FACES)
12 CLEANINESS OF THE SPOOL EXTERNALLY & INTERNALLY ACCEPTED
OTHERS:

FABRICATION & INSPECTION COMPLETED PIPE SPOOL RELEASED FROM WORK SHOP

CONS. CONTRACTOR CONTRACTOR NIOEC


NAME. SIGN DATE NAME. SIGN DATE NAME. SIGN DATE

TOTAL SHOP PREFAB. WEIGHT (kg) =

36
JULY, 2005 NIOEC-SP-50-05(0)

ATTACHMENT C (10/16)
NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY REPORT NO.:
JOB NO.
PROJECT: SH… OF…
……………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
LINE TEST PACKAGE No.:
ISOMETRIC LINE HISTORY SHEET TEST BLOCK No.:
P&ID No.:
VISUAL RT PT MT P.W.H.T Report
JOINT SIZE WELD WELDER DATE HARDNESS P.M.I
LOCATION REPORT REMARKS
NO INCH TYPE NO WELDED DATE Rep1 Rep2 Rep3 ACCEPT REPORT REPORT RJ1 RJ2 ACCEPT REPORT REPORT
No.

Construction Contractor Q/C Contractor NIOEC


NAME: NAME: NAME:
SIGN & DATE: SIGN & DATE: SIGN & DATE:

37
JULY, 2005 NIOEC-SP-50-05(0)

ATTACHMENT C (11/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
A/G PIPING CHECK LIST
SKETCH OF TEST PACKAGE ATTACHED WITH ALL LINES LISTED IN PRESSURE TEST REPORT
NO. CHECKED ITEMS C.C. CONTRACTOR NIOEC
1 CONFORMITY WITH P & ID; PLAN AND ISO DWGS
2 WELDING COMPLETED
3 NDE (RT. PT. MT) COMPLETED
4 PWHT AND HARDNESS TEST COMPLETED
PIPING COMPONENTS:
5 PIPES MATERIAL, THICKNESS, AND SIZE CORRECT.
6 CORRECT VALVES WITH PROPER BOLTS INSTALLED
7 FLANGES – TYPE AND RATING CORRECT
8 GASKETS – TYPE AND MATERIAL CORRECT
9 REDUCERS PROPERLY INSTALLED
10 VENTS AND DRAINS INSTALLED
11 OLETS FOR INSTRUMENTS CONNECTION INSTALLED
12 FINAL SUPPORTS
13 MISCELANOUS COMPONENTS (BLINDS REINFORCEMENT BTC)
PIPING FIELD INSTALLATION :
14 INSTALLATION STRAIGHT AND PLUMB
15 ELEVATIONS, SLOPES AND CLEARANCES CORRECT
PREPARATION FOR TEST:
16 LINE(S) PROPERLY SUPPORTED FOR TEST
17 SPRING HANGERS STOPPED
18 CHECK VALVE IN PROPER POSITION OR CHECK DISK
REMOVED
19 CONTROL, SAFETY VALVE, ORIFICE, GAGE GALSS
EXCLUDED

(ITEMS NOT INFLUENCING PRESSURE TEST TO BE INSTALLED LATER (IF ANY))


REMARKS:

CONS. CONTRACTOR CONTRACTOR NIOEC


LINES
RELEASED
FOR PRESSURE
TEST SIGN. DATE SIGN. DATE SIGN. DATE

38
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (12/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
FINAL INPECTION – ORIFICE FLANGES
ORIFICE FLANGE TAG NO. UNIT: PLANT / AREA
FLANGE RATING & FACING TAPE MATERIAL TAPS
SPECIFICATION
MARKED DESCRIPTION

LINE NO.
PIPELINE DRAWING NO.
SPECIFICATION LAYOUT/P
&ID
FLUID NAME

SERVICE GAS LIQUID STEAM


ORIENTATION OF ORIFICE VERTICAL
FLANGES/TAPS HORIZONTAL

SPOOL NO. SIZE JOINT NO. NDT. REPT. CONST. CONTRACTOR.


NO. CONTRACTOR
UPSTREAM ‘A’
DOWN STREAM ‘B’

(UPSTREAM ‘A’ / DOWNSTREAM ‘B’) A’ B’ CONST. CONTRACTOR.


CONTRACTOR
GRIND INTERNAL WELDS
STRAIGHT PIPE MINIMUM LENGTHS
PIPE INSIDE DIAMETER (INSTRUMENT ACCESS)
SEAL WELDING OF CONNECTIONS
HEAD PLUGS. JACKSCREWS. BOLTS. NUTS.
GASKETS

NOTES

CC SIGN. CONTRACTOR SIGN. NIOEC SIGN.

DATE DATE DATE

39
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (13/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PRE PRESSURE TEST LINE CLEANING

AREA/UNIT :

TEST PACKAGE :

TEST BLOCK NO. :

CLEANING METHOD :
WATER FLUSHING :
AIR BLOWING :
OTHER : INSPECTION RESULT

1- CHLORIDE CONTENT OF FLUSHING WATER FOR STAINLESS STEEL LINE


CHECKED AND SUITABLE
2- ITEMS TO BE EXCLUDED (SUCH AS PSV. CONTROL VALVE OPRFICE PLATE EXPANSION
JOINTS, THERMO WELLS, H/EXCHANGER, MACH, ETC. )
3- EQUIPMENT (VESSELS, H/EXCHANGER, MACH, ETC.)

4- CLEANING RESULT

5- ITEMS TO BE INSTALLED AFTER CLEANING AND BE INCLUDED IN PRESSURE


TEST CORRECT
REMARKS:

CONT : CONTRACTOR CONTRACTOR NIOEC

NAME: NAME: NAME:


SIGN : SIGN : SIGN :
DATE : DATE : DATE :

40
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (14/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PRESSURE GAUGE CALIBRATION RECORD

GAUGE NO. SERIAL NO. RANGE CALIBRATED VALID CERTIFICATE REMARK


DATE NO

41
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (15/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
PIPING PRESSURE TEST REPORT

AREA / UNIT : TEST PACKAGE :


P&ID DWG NO : TEST BLOCK NO:
TEST PRESS : BARG. ACTUAL PRESS BARG.
TEST MEDIUM : TEST DURATION :
AMB. TEMP: POST TEST FLUSHING/
AIR BLOWING METHOD :
REMARKS:

ISO DWG NO. LINE NO. ISO DWG NO. LINE NO.

CONT : CONTRACTOR CONTRACTOR NIOEC


PRESSURE TEST SIGN: SIGN: SIGN:
ACCEPTED DATE : DATE : DATE :
POST TEST SIGN: SIGN: SIGN:
DRAINING / AIR BLOWING
DATE : DATE : DATE :
DRYING COMPLETED

42
JULY, 2005 NIOEC-SP-50-05(0)
ATTACHMENT C (16/16)
NATIONAL IRANINAN OIL ENGINEERING AND
REPORT NO.:
CONSTRUCTION COMPANY
JOB NO.
PROJECT: SH… OF…
…………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.
POST TEST & RESTORATION INSPECTION REPORT
AREA/ UNIT: TEST PACKAGE :
DATE : TEST BLOCK NO. :
WORK ITEM REMARKS

INSPECTION RESULT :

CONSTRUCTION CONTRACTOR CONTRACTOR NIOEC

NAME : NAME : NAME :

SIGN. : SIGN. : SIGN. :

DATE : DATE : DATE :

43
JULY, 2005 NIOEC-SP-50-05(0)

ATTACHMENT D(1/1)
NATIONAL IRANINAN OIL ENGINEERING AND CONSTRUCTION COMPANY REPORT NO.:
JOB NO.
PROJECT: SH… OF…
……………………..
Contractor: Construction Contractor: UNIT
ITEM. NO.

RECOMMENDED PRESSURE GAUGE


FOR A/G PIPING PRESSURE TEST
NO. TEST PRESSURE RANGE PRESSURE GAUGE RANGE QUANTITY
(Bar.) (Bar.)
1 0–6 0 – 10
2 7 – 15 0 – 20
3 16 – 20 0 – 30
4 21 – 30 0 – 50
5 31 – 45 0 – 70
6 46 – 65 0 – 100
7 66 – 100 0 - 150

NOTE:
1- PRESSURE GAUGE SHOULD BE CALIBRATED AT THE INTERVAL OF MAX. SIX (6) WEEKS.

2- AFTER CALIBRATION, ALL GAUGES SHOULD BE ATTACHED WITH THE SEAL SHOWING GAUGE
SERIAL NO. & CALIBRATION DATE.

44